Burkert 8630 User manual

Type 8630
TOP Control Continuous
Operating Instructions
Bedienungsanleitung
Instructions de Service

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© 2001 Bürkert Werke GmbH & Co KG.
Operating Instructions 0507/11_EU-EN_00804575

8630 - 1
CONTENTS
Overall Operating Instructions
TOP Control
Continuous 8630
GENERAL NOTES
Symbols.......................................................................................................................................................................................................................................................... 10
Intended use ............................................................................................................................................................................................................................................ 10
Safety notes .............................................................................................................................................................................................................................................. 10
Protection from damage by electrostatic charging ......................................................................................................................... 11
Scope of delivery .............................................................................................................................................................................................................................. 11
Warranty conditions ...................................................................................................................................................................................................................... 11
Master code .............................................................................................................................................................................................................................................. 12
Transport, storage............................................................................................................................................................................................................................ 12
Disposal ......................................................................................................................................................................................................................................................... 12
SYSTEM DESCRIPTION
Valve types................................................................................................................................................................................................................................................. 14
Characteristics of the valve types...................................................................................................................................................................................... 15
Construction of TOP Control Continuous..................................................................................................................................................... 16
Illustrations (cover removed) ................................................................................................................................................................................................... 16
Design features ..................................................................................................................................................................................................................................... 17
Functional diagram as a positioner with single-acting actuator ............................................................................................................ 18
Operation as a positioner ..................................................................................................................................................................................................... 19
Schematic representation of positioning control .................................................................................................................................................. 20
Characteristics of the positioner software .................................................................................................................................................................. 21
* Alternative chapters or functions depending on device configuration

2 - 8630
CONTENTS
*Operation as a process controller (option)............................................................................................................................................... 22
Example of process control:TOP Control Continuous with sensor ................................................................................................... 22
Schematic representation of process control ......................................................................................................................................................... 23
Characteristics of the process controller software ............................................................................................................................................. 24
* Operation as a flow rate controller (option).......................................................................................................................................... 25
Characteristics of the flow rate controller software......................................................................................................................................... 25
Schematic representation of process control with flow rate controller ....................................................................................... 26
* Interfaces of the TOP Control Continuous in the multipole variant .................................................................. 27
* Interfaces of the TOP Control Continuous in the variants with
cable bushings.................................................................................................................................................................................................................................. 28
Technical data........................................................................................................................................................................................................................................ 29
Safety settings on failure of auxiliary electrical or pneumatic energy ......................................................................................... 29
Factory settings on the TOP Control Continuous ............................................................................................................................................. 30
Data of the TOP Control Continuous ............................................................................................................................................................................. 31
FIRST COMMISSIONING
Fluidic installation............................................................................................................................................................................................................................. 34
*Electrical installation - multipole connector ............................................................................................................................................ 35
*Electrical installation - connection terminals for cable bushings............................................................................ 36
Basic settings of the TOP Control Continuous..................................................................................................................................... 37
Settings in the menu items ....................................................................................................................................................................................................... 38
Entering the position setpoint in the AUTOMATIC mode.......................................................................................................................... 38
Manual opening and closing of the valve actuator in the MANUAL mode ............................................................................. 39
INSTALLATION
Installation of the valve ............................................................................................................................................................................................................ 42
Turning the TOP Control Continuous.................................................................................................................................................................. 42
Procedure ................................................................................................................................................................................................................................................... 42
Fluidic connection of the TOP Control Continuous....................................................................................................................... 43
* Alternative chapters or functions depending on device configuration

8630 - 3
CONTENTS
*Electrical connection - multipole connectors ....................................................................................................................................... 44
Marking of the multipole plugs or sockets and the contacts ................................................................................................................... 44
Output signals for SPS (circular plug M 16)............................................................................................................................................................. 45
Operating voltage (circular plug M 12)............................................................................................................................................................................ 45
Inductive proximity switches (circular socket M 8) ........................................................................................................................................... 45
Process value (circular plug M 8) ....................................................................................................................................................................................... 46
Process value with the option flow rate controller (2 circular plugs M 8)
Option: with temperature sensor input (3 circular plugs M 8) .............................................................................................................. 46
*Electrical connection - terminals for cable bushing.................................................................................................................... 47
Connection PCB of the TOP Control Continuous with screw terminals and jumpers ................................................ 47
Terminal configuration with cable bushings ............................................................................................................................................................ 47
Choice of binary outputs or process value input ............................................................................................................................................... 48
*Setting the inductive proximity switches (option)........................................................................................................................... 50
Opening the housing of the TOP Control Continuous ................................................................................................................................. 50
Positioning the inductive proximity switches .......................................................................................................................................................... 50
OPERATION AND CONTROLLER FUNCTIONS
Operating and display elements ................................................................................................................................................................................ 52
Operating levels .................................................................................................................................................................................................................................. 52
Commissioning and set-up as a positioner............................................................................................................................................... 53
Procedure for specifying the basic settings ............................................................................................................................................................ 53
Main menu for the settings on commissioning .................................................................................................................................................... 54
Description of the procedure .................................................................................................................................................................................................. 55
Configuring the supplementary functions.................................................................................................................................................... 59
Keys in the configuration level .............................................................................................................................................................................................. 59
Configuration menu.......................................................................................................................................................................................................................... 59
Supplementary functions ........................................................................................................................................................................................................... 62
Operating the process............................................................................................................................................................................................................... 86
Changeover between operating modes...................................................................................................................................................................... 86
Operating mode AUTOMATIC....................................................................................................................................................................................... 87
Meaning of the keys in the AUTOMATIC mode .................................................................................................................................................. 87
Display of the AUTOMATIC mode ..................................................................................................................................................................................... 87
Operating mode MANUAL .................................................................................................................................................................................................. 88
Meaning of the keys in the MANUAL mode ............................................................................................................................................................ 88
Display of the MANUAL mode .............................................................................................................................................................................................. 88
* Alternative chapters or functions depending on device configuration

4 - 8630
CONTENTS
OPERATING THE PROCESS CONTROLLER
Factory settings on the process controller................................................................................................................................................... 90
Setting up a process control system .................................................................................................................................................................... 90
Self-parametrization of the positioner - X.TUNE ............................................................................................................................... 91
Supplementary function P.CONTRL .................................................................................................................................................................... 91
Basic settings of the function
P.CONTRL ................................................................................................................................................................... 92
P.Q’LIN - Starting the routine for linearization of the process curve..................................................................... 105
Display during call-up and execution of the routine .......................................................................................................................................... 105
P.CO TUNE - Self-optimization of the process controller (process tune) ..................................................... 106
P.CO LEAK - Leakage characteristic for flow rate control ................................................................................................... 110
Operating the process ............................................................................................................................................................................................................... 112
Changeover between the operating modes ................................................................................................................................................................ 112
Operating mode AUTOMATIC ....................................................................................................................................................................................... 113
Meaning of the keys ......................................................................................................................................................................................................................... 113
Displays ........................................................................................................................................................................................................................................................ 113
Operating structure and procedures.................................................................................................................................................................................. 113
Manually changing the process setpoint ...................................................................................................................................................... 114
Operating mode MANUAL .................................................................................................................................................................................................. 114
Meaning of the keys ......................................................................................................................................................................................................................... 114
Displays ........................................................................................................................................................................................................................................................ 115
Operating structure and procedures.................................................................................................................................................................................. 115
PROFIBUS DP
General notes......................................................................................................................................................................................................................................... 118
Technical data ....................................................................................................................................................................................................................................... 118
Safety settings on bus failure ......................................................................................................................................................................................... 118
Interfaces....................................................................................................................................................................................................................................................... 119
Electrical connections ............................................................................................................................................................................................................... 119
Connection with one plugged bus connector ........................................................................................................................................................... 119
Connection with 2 plugged bus connectors .............................................................................................................................................................. 120
Operating voltage (circular plug M12) ............................................................................................................................................................................. 120
Bus connection (circular socket M12) ............................................................................................................................................................................ 120

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

6 - 8630
CONTENTS
Bus status display ........................................................................................................................................................................................................................... 144
Configuration example 1 ....................................................................................................................................................................................................... 145
Installation of the EDS file ......................................................................................................................................................................................................... 145
Address allocation .............................................................................................................................................................................................................................. 145
Offline parametrization of the device ............................................................................................................................................................................... 146
Online parametrization of the device ............................................................................................................................................................................... 147
Configuration example 2 ....................................................................................................................................................................................................... 148
Setting up the process map (mapping) .......................................................................................................................................................................... 149
MAINTENANCE AND ERROR CORRECTION ON THE POSITIONER
Maintenance ............................................................................................................................................................................................................................................ 152
Error messages and malfunctions .......................................................................................................................................................................... 152
Error messages on the LC display..................................................................................................................................................................................... 152
Other malfunctions ............................................................................................................................................................................................................................. 152
MAINTENANCE AND ERROR CORRETION ON THE
PROCESS CONTROLLER
Maintenance ............................................................................................................................................................................................................................................ 154
Error messages and malfunctions .......................................................................................................................................................................... 154
Error messages on the LC display..................................................................................................................................................................................... 154
Other malfunctions ............................................................................................................................................................................................................................. 156
Appendix

8630 - 7
CONTENTS
GENERAL RULES
Selection criteria for continuous valves .......................................................................................................................................................... 158
Characteristics of PID controllers............................................................................................................................................................................. 160
P component ............................................................................................................................................................................................................................................ 160
I component .............................................................................................................................................................................................................................................. 161
D component ............................................................................................................................................................................................................................................ 162
Superimposing the P, I and D components ............................................................................................................................................................... 163
Function of a real PID controller........................................................................................................................................................................................... 164
Rules for setting PID controllers ................................................................................................................................................................................ 165
Setting rules of Ziegler and Nichols (oscillation method) ............................................................................................................................ 165
Setting rules of Chien, Hrones and Reswick (controller output step method) ........................................................................ 166
OPERATING STRUCTURE
Operating structure of the TOP Control Continuous..................................................................................................................... 170
TABLE FOR POSITIONER
Table for noting your settings on the positioner .................................................................................................................................. 178
TABLE FOR PROCESS CONTROLLER
Tables for noting your settings on the process controller ..................................................................................................... 180
MASTER CODE
Code number .......................................................................................................................................................................................................................................... 182

8 - 8630
CONTENTS

8630 - 9
GENERAL NOTES
GENERAL NOTES
Symbols.............................................................................................................................................................................................................................................................. 10
Intended use ................................................................................................................................................................................................................................................ 10
Safety notes.................................................................................................................................................................................................................................................. 10
Protection from damage by electrostatic charging ............................................................................................................................. 11
Scope of delivery .................................................................................................................................................................................................................................. 11
Warranty conditions .......................................................................................................................................................................................................................... 11
Master code .................................................................................................................................................................................................................................................. 12
Transport, storage................................................................................................................................................................................................................................ 12
Disposal ............................................................................................................................................................................................................................................................. 12

10 - 8630
GENERAL NOTES
Symbols
The following symbols are used in these operating instructions:
marks a work step that you must carry out.
ATTENTION!
NOTE
marks important additional information, tips and recommendations.
marks notes on whose non-observance your health or the functioning of the device
will be endangered.
Safety notes
• Keep to standard engineering rules in planning the use of and operating the device!
• Installation and maintenance work are only allowed by specialist personnel using suitable tools!
• Observe the current regulations on accident prevention and safety during operation and maintenance
of the device!
• Switch off the supply voltage in all cases before intervening in the system!
• Note that in systems under pressure, piping and valves may not be loosened!
• Take suitable precautions to prevent inadvertent operation or damage by unauthorized action!
• Make sure that after an interruption to the electrical or pneumatic supply, the process starts up again in
a well-defined, controlled manner!
• On non-observance of these notes and unauthorized interference with the device, we will refuse all
liability and the warranty on device and accessories will become void!
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.

8630 - 11
GENERAL NOTES
Scope of delivery
Immediately after receipt of a shipment, make sure that the contents are undamaged and match the
scope of delivery stated on the packing slip. In general this consists of:
• Pneumatically actuated valve of type 2652, 2655, 2672, 2700, 2712, 2730, 2731 or 2731K with attached
TOP Control
Continuous,
• Operating Instructions for the TOP Control
Continuous and for the valve with pneumatic actuation.
If there are discrepancies, please contact immediately our customer service:
Bürkert Fluid Control Systems
Chr.-Bürkert-Str.13-17
Service Department
D-76453 Ingelfingen
Tel.: [phone]
Fax: [phone]
E-Mail: inf[email protected]uerkert.com
NOTE
Suitable cable plugs for the multipole connection are available as accessoires.
ATTENTION
EXERCISE CAUTION ON HANDLING!
ELECTROSTATICALLY SENSITITVE
COMPONENTS/MODULES
This device contains electronic components that are sensitive to
electrostatic discharge (ESD). Contact to electrostatically charged
persons or objects will endanger these components. In the worst
case, they will be immediately destroyed or will fail after
commissioning.
Observe the requirements of EN 100 015 - 1 in order to minimize
the possibility of, or avoid, damage from instantaneous electrostatic
discharge. Also take care not to touch components that are under
supply voltage.
Protection from damage by electrostatic charging
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.
Warranty conditions
This document contains no warranty promises.We refer in this connection to our General Conditions of
Sale and Business.The condition for the warranty is use of the unit for the intended purpose under the
specified application conditions.
ATTENTION!

12 - 8630
GENERAL NOTES
Master Code
Operation of this device can be locked by means of a freely selectable user code. Independent of this,
there exists an unchangeable master code with which you can execute all operative actions on the
device. This 4-digit code is to found on the last page of these operating instructions.
If required, cut out this code and keep it separate from these operating instructions.
Transport, storage
Transport and store the appliance in its original packing only.
ATTENTION!
Disposal
When disponsing of the appliance, observe the national standards for refuse disposal.
ATTENTION!

8630 - 13
SYSTEM DESCRIPTION
* Alternative chapters or functions depending on device configuration
SYSTEM DESCRIPTION
Valve types ................................................................................................................................................................................................................................................ 14
Characteristics of the valve types .......................................................................................................................................................................... 15
Construction of TOP Control Continuous.................................................................................................................................................... 16
Illustrations (cover removed) ........................................................................................................................................................................................ 16
Design features.............................................................................................................................................................................................................................. 17
Functional diagram as a positioner with single-acting actuator....................................................................................... 18
Operation as a positioner.................................................................................................................................................................................................... 19
Schematic representation of positioning control ................................................................................................................................. 20
Characteristics of the positioner software ................................................................................................................................................... 21
* Operation as a process controller (option) .......................................................................................................................................... 22
Example of process control: TOP Control Continuous with sensor ............................................................................ 22
Schematic representation of process control.......................................................................................................................................... 23
Characteristics of the process controller software............................................................................................................................ 24
* Operation as a flow rate controller (option)......................................................................................................................................... 25
Characteristics of the flow rate controller software.......................................................................................................................... 25
Schematic representation of process control with flow rate controller ................................................................... 26
* Interfaces of the TOP Control Continuous in the multipole variant ................................................................. 27
* Interfaces of the TOP Control Continuous in the variants with cable bushings ........................... 28
Technical data....................................................................................................................................................................................................................................... 29
Safety settings on failure of auxiliary electrical or pneumatic energy ...................................................................... 29
Factory settings on the TOP Control Continuous............................................................................................................................... 30
Data of the TOP Control Continuous.................................................................................................................................................................. 31

14 - 8630
SYSTEM DESCRIPTION
Various process valves from the Bürkert range can be combined with the TOP Control to suit different
applications.Y-, diaphragm or ball valves with control cones are suitable.
By the combination of the TOP Control with pneumatically actuated process valves, the functionality of
the Bürkert process valve series is extended. These valves, in connection with the TOP Control, may
also be employed in those control applications requiring continuous behaviour of the actuator.
TOP Control
Continuous
Type 8630
with Y-valve Type 2700
with diaphragm valve
Type 2730
with ball valve
Type 2655
with flat-seat valve
Type 2712
(here with flange connection)
with butterfly valve
Type 2672
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

8630 - 15
SYSTEM DESCRIPTION
Characteristics of the valve types
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.
Y-valves
Flat seat valves
Diaphram valves Ball valves Flap valves
Types • 2700
• 2712
• 2730 (plastic)
• 2731 (metal)
• 2731K (pipe housing)
• 2652 (2-part,VA)
• 2655 (3-part,VA)
• 2658 (plastic)
• 2672 (metal)
• 2675 (plastic)
Characteristic • Inlet flow under seat
• Non-impact closure
• Straight flow of
medium
• Self-adjusting packed
gland for very tight seal
• Medium is hermeti-
cally separated from
actuator and the
ambient
• Self-draining housing
design without dead
spaces
• Either flow direction
with low turbulence
flow
• May be steam
sterilized
• CIP compatible
• Non-impact closure
• Actuator and dia-
phragm are de-
tachable with the
housing
• Piggable
• Low and dead space
• insensitive to
contamination
• Lower pressure loss
than with other valve
types
• with 3-part ball valve,
seat and seal can be
exchaged while
installed
Note
Only usable as process
controller.
• insusceptible to dirt
• less pressure loss
compared to other
valve types
• good value for money
• smaller volume
Typical media • Water, steam and
gases
• Alcohols, oils, fuels,
hydraulic fluides
• Salt solutions, lyes
(organic)
• Organic solvents
• Neutral gases and
liquids
• contaminated, ab-
rasive and aggressive
media
• high purity or sterile
media
• high viscosity media
• Neutral gases and
liquids
• pure water
• slightly aggressive
media
• Neutral gases and
fluides
• slightly aggressive
media

16 - 8630
SYSTEM DESCRIPTION
Construction of TOP Control Continuous
Illustrations (cover removed)
Screw for adjusting the lower proximity
switch
Screw for adjusting the upper proximity
switch
Operating module with display and
keys
Exhaust air ports
(marked 3)
Control ports
(connected in the
factory)
Pressure supply port
(marked: 1)
Positioning system
with 2, 3 or 4 soleno-
id valves
Electrical connection module,
here with multipole connectors
Fixing screw for fixing the
TOP Control Continuous
on the drive
Max. torque 1.2 Nm

8630 - 17
SYSTEM DESCRIPTION
• Versions
for single and double acting valve actuators
•
Position sensor
very high resolution conductive plastic potentiometer, coupled without play to the piston rod of the
pneumatic actuator
•
Microprocessor controlled electronics
for signal processing, control and driving the valve
•
Operating module
The device is operated via 3 keys. 8-digit, 16-segment LC display for showing the setpoint or actual
value and for configuration and parametrization via menu functions.
•
Positioning system
With single-acting actuators, the positioning system consists of 2 solenoid valves; with double-acting
actuators of four solenoid valves. With single-acting actuators, one valve serves to pressurize the
pneumatic piston drive and another to exhaust it. Double-acting actuators contain 2 valves for
pressurization and 2 for exhausting.The solenoid valves work on the rocker principle and are driven
via the controller with a PWM voltage. This enables great flexibility with regard to actuator volumes
and floating speed. For larger pneumatic actuators, the solenoid valve are equipped with diaphragm
boosters.
As an option, with single-acting actuators, there are fast pressurizing/exhaust variants with an 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
" CUTOFF ") and on activation of a safety position of 0 or 100% (see section " BIN-IN ").
•
Position repeater (optional)
2 inductive proximity switches (initiators) or mechanical limit switches.
Attainment of an upper or lower position of the valve can be relayed via binary outputs e.g. to a PLC.
The end settings on the initiators can be adjusted by the owner by means of setscrews.
Design features
• Electrical interfaces
Multipole plug connector or cable bushing
•
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.
• Pneumatic interfaces
1/4’’- connectors in various threads
(G, NPT, RC)

18 - 8630
SYSTEM DESCRIPTION
Fuctional diagram as a positioner with single-acting actuator
Compressed air
supply
Actual process value
Process
controller
Setpoint position
Positioner
Positioning
system
Actual
position
Position
sensor
Process
setpoint
external
position
setpoint
TOP Control Continuous
Pneumatic
actuator
(single-acting)
Valve
(actuator)
Sensor
Positioning system
1: pressurizing valve
2: exhaust valve
Exhaust air
Actual process value
(flow rate, pressure, level,
temperature etc.)