Burkert 8630 Operating Instructions Manual

Operating Instructions Bedienungsanleitung Instructions de Service

Technische Änderungen vorbehalten. Sous resérve de modification techniques. © 2001 Bürkert Werke GmbH & Co KG. Operating Instructions 0507/11_EU-EN_00804575

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

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

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

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

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

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

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

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

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.

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.: (07940) 10-111 Fax: (07940) 10-448 E-Mail: [email protected] 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!

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!

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

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

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

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

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)

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.)

SYSTEM DESCRIPTION Operating as a positioner The actual position (POS) of the pneumatic actuator is measured via the position sensing system. The controller compares this actual value of the position with the setpoint (CMD) , which can be specified as a standard signal. If a control difference (Xd1) exists, a pulse-width modulated voltage signal is sent to the positioning system as the correcting variable. With single-acting actuators, if the difference is 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 a disturbance. Positioning system Sole- noid Continious valve Wegmeßsystem Position setpoint Positioner Position control loop Valve opening CMD POS Xd1 B1 E1 PK Z1 Position sensor

SYSTEM DESCRIPTION Schematic representation of positioning control 4 … 20 mA 0 … 20 mA 0 … 10 V 0 … 5 V DIR.CMD SPLTRNG CHARACT CUTOFF X.TIME X.CONTRL DBDx X.LIMIT DIR.ACT INP POS CMD INP POS CMD

SYSTEM DESCRIPTION Characteristics of the positioner software Supplementary function Effect Positioner with supplementary functions Tight-closing function Valve closes tight outside control range. A value is given (at %) from which the actuator is completely exhausted (at 0%) or pressurized (at 100 %). Stroke limitation Mech. valve piston movement only withhin a specified stroke range. Signal range splitting Splitting of the standard signal range over two or more TOP Control Continuous. Correction characteristic to match the operating curve Linearization of the process characteristic can be performed. Insensitivity range The positioner cuts in only above a specified control difference. Direction of action of the controller setpoint Reversal of the setpoint action direction Safety position Valve moves to a specified safety position. Hierarchical concept for simple operation with the following levels Process operation In this level your switch between automatic and manual operation. Configuration In this level you specify on commissioning certain basic functions and configure supplementary functions as needed.

SYSTEM DESCRIPTION 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. * Operation as a process controller (option) Process Transmitter Process setpoint Process controller Valve opening CMD PV Xd2 SP Z2 Process variable Positioning system Soleno- id valves Continuous Valve Position sensor Positioner Valve opening XPOS Xd1 B1 E1 PK Z1 Process control loop Example of process control: TOP Control Continuous with sensor Position control loop

SYSTEM DESCRIPTION Characteristics of the process controller software Supplementary function Effect Positioner with supplementary functions Tight-closing function Valve closes tight outside control range. A value is given (at %) from which the actuator is completely exhausted (at 0%) or pressurized (at 100%). Stroke limitation Mech. valve piston movement only within a specified stroke range. Signal range splitting Splitting of the standard signal range over two or more TOP Control Continuous. Correction characteristic to match the operating curve Linearization of the process characteristic can be performed. Insensitivity range The positioner cuts in only after a specified control difference. Direction of action of the controller setpoint Reserval of the setpoint action direction Safety position Valve moves to a specified safety position Analog feedback (option) Feedback of the position/process values Binary outputs Connectable process controller with the following characteristics (Option) Controller structure PID Parameters that can be set Proportional action factor, reset time, rate time and operating point Scalable input Decimal point position, upper and lower sacle valures of process value and setpoint Method of setpoint setting Setting either via standard signal input or via keys Hierarchical concept for simple operation with the following levels Process operation In this level your switch between automatic and manual operation. Configuration In this level you specify on commissioning certain basic functions and configure supplementary functions as needed.

SYSTEM DESCRIPTION * Operation as a flow rate controller (option) The flow rate controller is a special type of process controller. The process value (PV) is not measured directly via an analog input but calculated in the device by the dp method. According to the algorithm, the flow rate is dependent on the parameters pressure before valve (p1), pressure after valve (p2), me- dium 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. In the case of the flow rate controller, the process parameters are either the volumetric flow rate or, for special applications, the transport velocity at the end of a pumping section. The volumetric flow rate is represented in m3/h STP, i.e. referred to 0 °C (medium temperature) and a gas pressure of 1013 mbar (abs). There are special applications for flow rate controllers in which a pumping section is set up after the valve, in which bulk goods enter via an airlock. These bulk goods are blown through the pumping section by the pumping pressure that builds up behind the valve. The transport velocity corresponds to the volumetric flow rate of the medium, referred to the piping diameter of the pumping section. However, it is not specified for standard conditions, but reflects the velocity of the gas particles at the existing medium temperature. The diameter is entered in the operating menu. Characteristics of the flow rate controller software The flow rate controller offers the same functions as the process controller. 8630 Flow rate controller e.g. valve type 2712 PV kv value Pressure Temperature (optional) T p1 p2 Pressure p1 p2

SYSTEM DESCRIPTION Schematic representation of process control with flow rate controller

SYSTEM DESCRIPTION * 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 Input for process setpoint 4..20 mA Frequency Pt 100 * Flow rate controller Binary input 24 V DC Sup- ply Inputs Outputs Operating unit TOP Control Continuous (multipole - variant) 2 binary outputs *Initiators 1 + 2 Analog position feedback 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. * Note: Inputs for process value with flow rate controller (option): p1, p2, T (optional). The standard process controller inputs (4 ... 20 mA, frequency, Pt 100) and the initiators cannot be used with this option.

SYSTEM DESCRIPTION * Interface of the TOP Control Continuous in the variants with cable bushings Input for process setpoint* 4..20 mA Frequency Pt 100 (alternative to binary out- puts) 24 V DC Sup- ply Inputs Outputs Operating unit 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. NOTE TOP Control Continuous Type 8630 is a 3-conductor device, i.e. the voltage supply (24 V DC) is separate from the setpoint signal. Inputs for position or process setpoint 4..20 mA 0..20 mA 0..10 V 0..5 V Binary input

SYSTEM DESCRIPTION Technical data Actuator type Designation Safety position after failure of auxiliary energy Electrical Pneumatic Single-acting down down SFA Single-acting up up SFB Double-acting down / up undefined SFI (depending on connection of control conductors) Safety settings on failure of auxiliary electrical or pneumatic energy

SYSTEM DESCRIPTION Factory settings on the TOP Control Continuous Function Factory setting ACTFUNC FUNCSNGL INPUT INP 4'20 A CHARACT CHA LIN DIR.CMD DIR.CRISE CUTOFF CUT 0 %, CUT 100 % DIR.ACT DIR.ARISE SPLTRNG SR 0 (%), SR 100 (%) X.LIMIT LIM 0 %, LIM 100 % X.TIME T.OPN Values calculated by AUTOTUNE T.CLS Values calculated by AUTOTUNE After execution of SETFACT: 1 s OUTPUT OUT ANL: OUT POS OUT 4´20 A OUT BIN: OUT DEV DEV 5.0 NO BIN-IN B.IN SPOS SPOS 000 NO Function Factory setting X.CONTRL X.CO DBND 1 % X.CO PARA KX Values calculated by AUTOTUNE KX Values calculated by AUTOTUNE After execution of SETFACT: 1 P.CONTRL P.CO DBND 1 % P.CO PARA KP 1.00 TN 999.9 TV 0.0 X0 0 P.CO SETP SETP INT P.CO INP INP 4´20 A P.CO FILT 0 P.CO SCAL PV 000.0, PV 100.0 P.CO TUNE D’ACT P.CO KV FACT P.CONTRL with flow rate controller P.CO DBND 1 % P.CO PARA KP 1.0 TN 999.9 TV 0.0 X0 0 P.CO SETP SETP INT P.CO INP INP P1’P2 P.CO FILT 0 P.CO SCAL PV 000.0, PV 100.0 P.TYP FLOW UNIT M3/H TEMP MAN DENS 1.293 DIAM 0025 P.CO TUNE D’ACT P.CO KV FACT CODE CODE 0000 NOTE The functions and factory settings shown in grey are valid for the optional flow rate control.

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) CONFORMITY TO THE FOLLOWING STANDARDS CE conformity wer. EMC Guideline 89/336/EWG MECHANICAL DATA Dimensions see data sheet Housing material TOP Control outer: Noryl (PPE/PA), PSU, inner: PA 6 Dichtmaterial NBR ELECTRICAL DATA Connections Choice between multipole connector or 3 bushings M 16 x 1.5 with screw terminals 0.14 ... 1.5 mm² Voltage supply 24 V DC ± 10 % residual ripple 10 % No industrial DC! Power consumption < 5 W Housing internal temperature indication - 55 ... + 125 °C, accuracy ± 2 °C Input resistance for 180 Ω at 4 - 20 mA/resolution 12 bit actual value signal 17 kΩ at frequency, 0 ... 1000 Hz / 1‰ of mean > 300 Vss sinus, square-wave, sawtooth PT-100 - 20 ... + 220 °C, resolution < 0.1 °C Input resistance for 180 Ω at 0/4 - 20 mA/resolution 12 bit setpoint signal 19 kΩ at 0 - 5/10 V /resolution 12 bit Protection class 3 to VDE 0580 Analog position feedback: max. current for voltage output 0 ... 5/10 V 10 mA max. burden for current output 0/4 ... 20 mA 560 Ω Inductive proximity switch current limitation 100 mA Data of the TOP Control Continuous ATTENTION! The TOP Control Continuous is not suitable for outdoor use.

SYSTEM DESCRIPTION Binary outputs electrically isolated current limitation 100 mA, output is clocked Binary input electrically isolated 0 ... 5 V = log "0", 10 ... 30 V = log "1" inverted output reversed accordingly PNEUMATIC DATA Control medium Qualitiy Classes to DIN ISO 8573-1 Dust content Class 5 max. particle size 40 µm, max. particle density 10 mg/m3 Water content Class 3 max.pressure dew point - 20 °C or min. 10 deg. below the lowest operating temperature Oil content Class 5 max. 25 mg/m³ Temperature range of compressed air -10 ... + 50 °C Pressure range 3 ... 7 bar Supply pressure variation max. ± 10 % during operation Air flow capacity of control valve 100 lN / min STP (for pressurizing and exhausting) (QNn - value acc. to definition on pressure drop from 7 to 6 bar abs.) Intrinsic air consumption with zero control output 0.0 lN/min STP Connections G 1/4’’ internal thread G / NPT / RC

FIRST COMMISSIONING 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 * Alternative chapters or functions depending on device configuration

FIRST COMMISSIONING Fluidic installation ➔Install the valve according to operating instructions! ➔Connect supply pressure to connection "1" (3 .. 7 bar; instrument air, free from oil, water and dust) ➔Attach the exhaust line or silencer to connection "3"! 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. Remove the protective caps from the valve and and the TOP Control Continuous! NOTE

FIRST COMMISSIONING * Electrical installation - multipole connector Configuration of the circular connector M 12 Pin Allocation External connection 1 + 24 V 2 not connected 3 GND 4 not connected 24 V DC ± 10 % max. residual ripple 10 % A B + (0/4 ... 20 mA or 0 ... 5 / 10 V) GND 3 1 M12 M16 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. ➔Apply the setpoint signal to the circular connector M16 ➔ Apply the supply voltage to the circular connector M12 Configuration of the circular connector M 16 Allocation Setpoint + (0/4 ... 20 mA or 0 ... 5/10 V) Setpoint GND External connection/Signal level Pin B A NOTE Further installation notes are to be found in the chapter Installation.

FIRST COMMISSIONING 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. NOTE Further installation notes are to be found in the chapter Installation. ➔Remove the cover with the cable bushings to gain access to the terminals. This is done by unscrewing the 4 self-tapping screws. ➔Apply the setpoint signal and the supply voltage to the respective terminals (see Terminal configuration with cable bushings). Terminal Allocation External connection 1 Setpoint + 2 Setpoint GND 5 Operating voltage + 6 Operating voltage GND 24 V DC ± 10 % max. residual ripple 10 % 2 1 + + (0/4 ... 20 mA or 0 ... 5/10 V) GND 5 6 Terminal configuration with cable bushings * Electrical installation - connection terminals for cable bushings screw terminals

FIRST COMMISSIONING Basic settings of the TOP Control Continuous Jump over on first commissioning Configuration of the keys MANUAL/AUTOMATIC-key Switch between main and subitems, e.g. ACT FUNC - FUNCSNGL Arrow keys Switch between equal-ranking menu items, e.g. ACTFUNC - INPUT AUTOMATIC MODE MANUAL MODE

FIRST COMMISSIONING 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 display options: Display: • Actual position of valve actuator POS__XXX (0 ... 100 %) • Setpoint position of valve actuator CMD__XXX (0 ... 100 %) • Input signal for setpoint position INP__XXX (here identical to setpoint position) (0 ... 5/10 V or 0/4 ... 20 mA) • Temperature inside TOP Control Continuous housing TEMP_XX.X (in °C) Settings in the menu items ACTFUNC Actuator function FUNC SNGL - single-acting FUNC DOUB - double-acting INPUT Standard signal INP 4’20A - Current 4 ... 20 mA INP 0’20A - Current 0 ... 20 mA INP 0’10V - Voltage 0 ... 10 V INP 0’5V - Voltage 0 ... 5 V ADDFUNCT Jump over X.TUNE Initiate self-parametrization 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

FIRST COMMISSIONING 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. NOTE Select the display POS_XXX , in this case the actual position of the valve actuator can be checked.

INSTALLATION INSTALLATION Installation of the valve ............................................................................................................................................................................................................ 42 Turning the TOP Control Continuous ................................................................................................................................................................. 42 Procedure ............................................................................................................................................................................................................................................... 42 Fluidic connection of the TOP Control Continuous ....................................................................................................................... 43 * 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 with 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 * Alternative chapters or functions depending on device configuration

INSTALLATION 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 be connected. For dimensions and threads, see data sheet for the process valve. NOTE NOTE 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 to attach the cable or hoses, the TOP Control Continuous may be rotated relative to the pneumatic actuator. Procedure ➔ Disconnect the fluidic connection between TOP Control Continuous and pneumatic actuator. ➔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. ➔Retighten the fixing screw with 1.2 Nm moderate torque. ➔Remarke the fluidic connection between TOP Control Continuous and pneumatic actuator, using longer hoses if necessary. ATTENTION! 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! ATTENTION! To assure leak tightness of the device (IP65), the screw for connecting TOP Control Continuous and process valve shall be tightened with a torque not exceeding 1.2 Nm!

INSTALLATION Fluidic connection of the TOP Control Continuous ➔Apply the supply pressure to connection“1" (3..7 bar, instrument air, free from oil, water and dust) ➔Attach the exhaust line or silencer to connection „3“ NOTE 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 %). 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.

INSTALLATION * Electrical connection - multipole connectors Marking of the multipole plugs or sockets and the contacts M16 M8 M12 M8 Output signals to SPC Process value Initiators (inductive proximity switches) Operating voltage ATTENTION! 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 Bürkert Service directly. With Profibus DP or DeviceNet: The markings of the multipole plugs and sockets, and the contacts are to be found in the respective chapters. NOTE TE 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).

INSTALLATION Operating voltage (circular plug M 12) Pin Allocation External connection 1 + 24 V 2 not connected 3 GND 4 not connected 24 V DC ± 10 % max. residual ripple 10 % Pin Allocation Signal level 1 Proximity switch 1 + (NO) 2 Proximity switch 1 GND 3 Proximity switch 2 + (NO) 4 Proximity switch 2 GND open / 24 V +24 V DC GND GND 1 2 S1 open / 24 V +24 V DC GND GND 3 4 S2 Inductive proximity switches (circular socket M 8) Output signals for SPS (circular plug M16) Pin Allocation External connection/signal level A Setpoint GND B Setpoint + (0/4..20 mA or 0..5/10 V) C Analog position feedback + D Analog position feedback GND E Binary output 1 F Binary output 2 G Binary output GND H Binary input + J Binary input GND K not connected L not connected M not connected A B + (0/4 ... 20 mA or 0..5/10 V) completely isolated electrically GND 24 V / 0 V 24 V / 0 V GND E F G H J GND + 0 ... 5 V (log. 0) 10 ... 30 V (log. 1) GND C D + (0/4 ... 20 mA or 0 ... 5/10 V) completely isolated electrically

INSTALLATION Input type No. of plugs Pin Configuration Jumper ext. connection internally supplied transmitter* 1 1 2 3 + 4 + 24 V - supply to transmitter p1 4 ... 20 mA - output from transmitter p1 n.c. 2 1 2 3 + 4 + 24 V - supply to transmitter p2 4 ... 20 mA - output from transmitter p2 n.c. Option: temperature transmitter 3 1 2 3 + 4 + 24 V - supply to transmitter 4 ... 20 mA - output from temperature transmitter n.c. * May be set via software (section Procedure for specifying the basic settings) ** The jumper is situated on the connection board of the TOP Control Continuous (see next page) Process value (circular plug M 8) For line compensation reasons, connect sensor Pt-100 via 3 conductors. PIN 3 and PIN 4 must be bridged at the sensor. NOTE Process value with the option flow rate controller (2 circular plugs M8) Option: with temperature sensor input (3 circular plugs M8) Input type * Pin Allocation Jumper** External connection 4 ... 20 mA 1 + 24 V supply transmitter - internal 2 Output Transmitter supply 3 GND 4 bridge to GND (GND from 3-conductor transmitter) 4 ... 20 mA 1 not connected - external 2 Process actual + supply 3 not connected 4 Process actual - Frequency 1 + 24 V - supply sensor - internal 2 Clock input + supply 3 Clock input - (GND) 4 not connected Frequency 1 not connected - external 2 Clock input + supply 3 Clock input - 4 not connected Pt-100 1 not connected (see 2 process actual 1(current supply) Note 3 process actual 3 (GND) below) 4 process actual 2 (compensation) 2 4 Pt 100 Clock + Clock - Clock + Clock - 3 2 1 +24 V 2 3 3 * With external supply of the sensors, the mass of the standard signal must be connected to the mass of the supply voltage. Circular plug M12 2 4 4 ... 20 mA GND

INSTALLATION * Electrical connection - terminals for cable bushing ➔Remove the cover with the cable bushings to gain access to the screw terminals. This is done by unscrewing the 4 self-tapping screws. Connection PCB of the TOP Control Continuous with screw terminals and jumpers Terminal Allocation External connection 1 Setpoint + 2 Setpoint GND 3 Analog position feedback + 4 Analog position feedback GND 5 Operating voltage + 6 Operating voltage GND 24 V DC ± 10 % max. residual ripple 10 % 2 1 + + (0/4 ... 20 mA or 0 ... 5/10 V GND 5 6 Terminal configuration with cable bushings GND 3 4 + (0/4 ... 20 mA or 0 ... 5/10 V) completely isolated electrically ATTENTION! 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 Bürkert Service directly. NOTE 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).

INSTALLATION ➔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. ➔The input type is set via the configuration menu (see Procedure for specifying the basic settings). Choice of binary outputs or process value input Input type* Jumper Terminal Allocation External connection 4 ... 20 mA 7 + 24 V input transmitter internal 8 Output transmitter supply 9 Bridge to GND (GND from 3-conductor transmitter) 10 GND Frequency 7 + 24 V supply sensor internal 8 Clock input + supply 9 not connected 10 Clock input - (GND) 4 ... 20 mA 7 not connected external 8 Process actual + supply 9 Process actual - 10 not connected Frequency 7 not connected external 8 Clock input + supply 9 not connected 10 Clock input - Pt-100 7 not connected (see 8 Process actual 1 (current supply) Note 9 Process actual 2 (compensation) below) 10 Process actual 3 (GND) 7 + (4 ... 20 mA) 8 9 GND Clock + 8 10 Clock - Clock - (GND) 10 8 7 +24 V Clock + 8 Terminal allocation on selection of process value input: Jumper Terminal Allocation External connection 7 Binary output 1 8 Binary output 1 9 Binary output 2 10 Binary output 2 8 7 9 10 24 V / 0 V NC / NO GND 24 V / 0 V NC / NO GND For reasons of line compensation, connect the Pt 100 sensor over 3 conductors. Be sure to bridge terminals 9 and 10 at the sensor. NOTE 8 10 9 Pt100 9 10

INSTALLATION Terminal allocation with binary outputs Terminal Allocation External connection 11 Binary input + 12 Binary input GND 11 12 GND + 0 ... 5 V (log. 0) 10 ... 30 V (log. 1)

INSTALLATION Opening the housing of the TOP Control Continuous ➔Remove any lead seals or fastenings present between cover and housing. ➔Turn the cover anticlockwise and lift it off. Positioning the inductive proximity switches ➔The inductive proximity switches are positioned vertically with one adjusting screw each: * Setting the inductive proximity switches (Option) Screw to adjust the lower proximity switch Screw to adjust the upper proximity switch Turning clockwise causes upward adjustment ATTENTION! Turning anticlockwise causes downward adjustment ATTENTION! In order to set the inductive proximity switches, the housing of the TOP Control Continuous must opened. Switch off the operating voltage before making this intervention! 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).

OPERATION AND CONTROLLER FUNCTIONS OPERATION AND CONTROLLER FUNCTION 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

OPERATION AND CONTROLLER FUNCTIONS 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. Arrow key up Arrow key down MANUAL/AUTOMATIC KEY LED (yellow) in the MANUAL/AUTOMATIC-key (see chapter Operating the process controller) 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 Configuration level Basic funktions Supplemen- tary functions MANUAL AUTO- MATIC 5 sec End

OPERATION AND CONTROLLER FUNCTIONS Configuration of the keys MANUAL/AUTOMATIC-key Switch between main and sub-menu items, e.g. ACT FUNC - FUNCSNGL Arrow keys Switch between eual-ranking menu items, e.g. ACTFUNC - INPUT 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: • Specify the function of the pneumatic actuator used. • Specify the standard signal input for setpoint setting (4..20 mA, 0..20 mA, 0..10 V or 0..5 V). • Start the automatic adaptation of the positioner to the current operating conditions (AUTOTUNE). Factory setting of the positioner Function Factory setting ACTFUNC FUNCSNGL INPUT INP 4'20A CHARACT CHA LIN DIR.CMD DIR.CRISE CUTOFF CUT = 0 %; CUT = 100 % DIR.ACT DIR.ARISE SPLTRNG SR = 0 (%); SR = 100 (%) X.LIMIT LIM = 0%, LIM = 100% X.TIME T.OPN Values determined by AUTOTUNE T.CLS Values determined by AUTOTUNE After execution of SETFACT: 1 s Function Factory setting OUTPUT OUT ANL: OUT POS OUT 4'20 A OUT BIN: OUT DEV DEV 5.0 NO BIN-IN B.IN SPOS SPOS 000 NO X.CONTROL X.CO DBND 1 % X.CO PARA KX Values determined by AUTOTUNE KX Values determined by AUTOTUNE After execution of SETFACT: 1 CODE CODE 0000

OPERATION AND CONTROLLER FUNCTIONS Main menu for the settings on commissioning Jump over on first commissioning 5 s 5 s AUTOMATIC MODE MANUAL MODE

OPERATION AND CONTROLLER FUNCTIONS 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, ...). Description of the procedure - single-acting - double-acting NOTE At the level of the sub-menu items, the selected function is shown by the three or four characters 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 TOP Control. This function is marked on the rating plate of the actuator. INPUT - Selected standard signal ➔ ➔ ➔ ➔ ➔Enter under this menu item the standard signal used for the setpoint. - Current 4 ... 20 mA - Current 0 ... 20 mA - Voltage 0 ... 10 V - Voltage 0 ... 5 V

OPERATION AND CONTROLLER FUNCTIONS Start the automatic adaptation of the positioner to the current operating conditions X.TUNE - Autotune for positioner ➔Start the program for automatic parametrization of the TOP Control Continuous via the menu item X.TUNE. The following functions are initiated automatically: • 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. • Setting of the controller parameters of the positioner. Optimization is done according to the criteria: as short a correcting time as possible 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. ADDFUNCT See section Configuring the supplementary functions. ➔Jump over this menu item on first commissioning. NOTE The basic settings onthe TOP Control Continuous are made in the factory. On 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). NOTE To cancel AUTOTUNE, operate both arrow keys at the same time and select X.TUN BRK . Display Description TUNE 5 Countdown from 5 to 0 start of AUTOTUNE TUNE 4 : TUNE 0 ¦ 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) ¦ X.T TCLS : TUNE-END Flashing display ➞ end of AUTOTUNE X.ERR X Message on occurrence of an error (Indication right: Error number, see chapter Maintenance and controller fault rectification)

OPERATION AND CONTROLLER FUNCTIONS 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. The following parameters, which are automatically determined during X.TUNE, may be manually present or adjusted afterwards. TUNE-END - Return to main menu 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 continues with the setting of the positioning system and optimization of the positioner. NOTE If manual presetting of the end positions by means of TUNE-POS is necessary, it must be done before execution of AUTOTUNE. ATTENTION! During execution of the AUTOTUNE function, the valve moves on its own away from its current position. For this reason, never execute AUTOTUNE while the process is running! release move to max. position move to min. position change min. PWM T.V. for pressurizing valve change min. PWM T.V. for venting valve display of opening time (s) display of closing time (s) 5 s (Countdown) AUTOTUNE MANUAL TUNE

OPERATION AND CONTROLLER FUNCTIONS 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. 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-AIR, 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 The function TUNE-PWM must be executed after AUTOTUNE! NOTE The function TUNE-AIR must be executed after AUTOTUNE! ATTENTION! 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 ➔ ➔ ➔ ➔ ➔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).

OPERATION AND CONTROLLER FUNCTIONS Configuring the supplementary functions Configuration menu Switching between the process operating level and the configuration level Keys in the configuration level 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. Press key in Menu in a selected and confirmed menu item Scroll up Increment (increase) numeric value (select) Scroll down Decrement (decrease) numeric value (select) Press key in Menu in menu ADDFUNCT confirm selected menu item Confirm selected menu item of supplementary 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. Process operating level Configuration level Basic functions Supple- mentary menu MANUAL AUTO- MATIC 5 sec END

OPERATION AND CONTROLLER FUNCTIONS ➔Select in the main menu the item ADDFUNCT. ➔ By pressing the MANUAL/AUTOMATIC key, enter the supplementary menu. ➔With the arrow keys, select the desired supplementary function. ➔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. ➔In the main menu, enter the parameters for the supplementary functions. Deletion of supplementary functions from the main menu Addition of supplementary functions to the main menu ➔ ➔ ➔ ➔ ➔ 5 s 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 menu, which can then be specified. ➔Select in the main menu the item ADDFUNCT. ➔By pressing the MANUAL/AUTOMATIC key, enter the supplementary menu. ➔With the arrow keys, select a supplementary function marked with (*). ➔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. NOTE By removing a function from the main menu, the settings previously made under this function are again invalidated. Numeric values are set in the menu items provided by pressing the keys „arrow up“ (increment value) or „arrow down“ (decrement value) one or more times. In the case of 4-digit numbers, only the flashing digit can be set with the arrow keys. By pressing the MANUAL/AUTOMATIC key, you can switch to the next digit. Setting of numeric values

OPERATION AND CONTROLLER FUNCTIONS Principle of adding supplementary functions to the main menu

OPERATION AND CONTROLLER FUNCTIONS Supplementary Functions Select the transfer characteristic between input signal ans stroke (correction characteristic) Tight closure function for positioners or process controllers (if activated) Sense of action between input signal ans setpoint position Allocation of state of pressurization of actuator chamber (Port 21) to actual position Signal range splitting; input signal in % for which the valvetransverses the entire stroke Limitation of mechanical stroke range Parametrization of positioner (Parametrization of the PID process controller). Without function in the version as positioner! Code protection for settings Limitation of correcting speed Activation of binary input (Configuration of the outputs, only with supplementary board for analog feedback or binary outputs) Calibration Reset to factory settings Enter safety position Configure error recognition signal level Configuration of the serial interface ADDFUNCT CUTOFF DIR.CMD CHARACT DIR.ACT SPLTRNG X.LIMIT X.TIME X.CONTRL P.CONTRL CODE BIN-IN OUTPUT CAL USER SETFACT SIG-ERR SAFEPOS ENDFUNCT SER-I/O

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. The flow characteristic kv = f(s) describes the flow through a valve, expressed by the kv 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 kv value dkv (dkV = nlin * ds). With an equipercentile characteristic, a change in stroke ds corresponds to an equipercentile change in kv value (dkV/kV = ngleichpr * ds). The operating characteristic Q = f(s) represents the relationship between the volumetric flow Q 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. Linear characteristic Equipercentile characteristic 1:25 Equipercentile characteristic: 1:33 Equipercentile characteristic 1:50 Inverse equipercentile characteristic 25:1 Inverse equipercentile characteristic 33:1 Inverse equipercentile characteristic 50:1 User-defined characteristic, freely programmable via fixed points

OPERATION AND CONTROLLER FUNCTIONS Normalized position setpoint [%] (CMD) 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 %. 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 %). Next to it is the value of the function (initially 0 %). With the arrow keys, set a value of the function between 0 and 100 %. 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 %). The display returns to the menu item CHARACT. Normalized valve stroke [%] (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 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 characteristic via fixed points or have it calibrated automatically.

OPERATION AND CONTROLLER FUNCTIONS Valve stroke [%] (POS) Setpoint signal [%] (CMD) Entering the fixed points: Valve stroke [%] (enter with arrow keys) Position setpoint [%] (fixed point) Return to CHARACT Example of a programmed characteristic NOTE The fixed points that were entered should be noted in the table in the Appendix.

OPERATION AND CONTROLLER FUNCTIONS Setting range: 75 ... 100 % Setting range: 0 ... 25 % Valve stroke [%] (POS) Setpoint [%] (CMD) CUTOFF Tight closure function for positioners or process controllers Factory setting: CUT = 0 %; CUT = 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 in the display a flashing MIN or MAX symbol. Tight-closing threshold exhaust (0 = inactive); setting range: 0..25 %. Tight-closing threshold pressurize (100 = inactive); setting range: 75 ... 100 % Limits refer to process setpoint (SP) Limits refer to position setpoint (CMD) Menu appears only with activated PID controller

OPERATION AND CONTROLLER FUNCTIONS Inputsignal (INP) 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 (e.g. 4 mA or 0 V ➔ ➔ ➔ ➔ ➔ 0 %, 20 mA or 5/10 V ➔ ➔ ➔ ➔ ➔ 100%) Inverse sense of action (e.g. 4 mA or 0 V ➔ ➔ ➔ ➔ ➔ 100%, 20 mA or 5/10 V ➔ ➔ ➔ ➔ ➔ 0%) Setpoint position (CMD)

OPERATION AND CONTROLLER FUNCTIONS 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 (exhausted ➔ ➔ ➔ ➔ ➔ 0 %; pressurized ➔ ➔ ➔ ➔ ➔ 100 %) Inverse Wirkungsrichtung (entlüftet ➔ ➔ ➔ ➔ ➔ 100 %; belüftet ➔ ➔ ➔ ➔ ➔ 0 %) State of pressurization Pressurized Exhausted Actual position (POS)

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 (%); SR = 100 (%) Entering the minimum value of the input signal in % (0 ... 75 (%) of the standard signal range) Entering the maximum value of the input signal in % (25 ... 100 (%) of the standard signal rage) Splitting the standard signal range into tow setpoint ranges 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. NOTE This function is only effective when operating as a positioner. XX XXX Valve stroke [%] (POS) Setpoint range TOP Control Continuous 1 Setpoint range TOP Control Continuous 2 Setpoint range [mA] (INP)

OPERATION AND CONTROLLER FUNCTIONS X.LIMIT Limitation of the mechanical stroke range Factory setting: LIM = 0%, LIM = 100% 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. Entering the start value of the stroke range in %, 0 ... 50 % of the overall stroke Entering the end value of the stroke rage in %, 50 ... 100 % of the overall stroke The minimum separation between LIM and LIM is 50 %. XXX XX Setpoint [mA] (INP) limited stroke Limited stroke [%] (POS) Physical stroke [%] (POS) unlimited stroke Control range in automatic mode Correcting range in manual mode

OPERATION AND CONTROLLER FUNCTIONS Effect of limitation of the opening speed after a step in the setpoint X.TIME Limitation of the correcting speed Factory setting: 1 s Opening time for full stroke (in seconds) Closing time for full stroke (in seconds) If the correcting speed is to be limited, values can be entered for T:OPN and T.CLS that lie between the minimum values determined by X:TUNE and 60 s. NOTE When executing the function X.TUNE, the minimum opening and closing time for T.OPN and T.CLS is automatically entered for the full stroke. In this way it is possible to traverse at maximum speed. XX XX Valve stroke [%] (POS, CMD) Setpoint Actual value T.OPN t NOTE If positioning times < 1 s are determined from the AUTOTUNE, X.TIME is automatically copied to the main menu and the relevant value is set to 1 s.

OPERATION AND CONTROLLER FUNCTIONS Insensitivity range (dead band) of the positioner Entry of the dead band in %, referred to the scaled stroke range; i.e. LIM 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. X.CONTRL Parametrization of the positioner XXXX XXXX Xd1 Xd1 Xd1' Xd1' to controller Dead band Position actual value (POS) Position setpoint (CMD) Control difference Parameters of the positioner Gain factor of the positioner (to close the valve) Gain factor of the positioner (to open the valve) End of parametrization of positioner. Jump back to X.CONTRL. NOTE If, 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.

OPERATION AND CONTROLLER FUNCTIONS CODE Code protection for the settings Factory setting: CODE 0000 If the code protection is activated, entry of the code will be demanded on every protected operative manipulation: Change the flasching digit Confirm the digit and switch to next digit Entry of the 4-digit code. Locking of all functions that cloud change the operating status of the device. (The display on the display unit can be switched over). 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.)

OPERATION AND CONTROLLER FUNCTIONS SAFEPOS Entering the safety position Factory setting: 0 % SAFEPOS SPOS XXX Enter safety position (0 ... 100 %)* With the fast pressurize / fast vent variant, two valves are driven in each case to obtain faster pressurizing and venting. * When the safety position is 0 % or 100 %, the actuator will be fully vented or pressurized as soon as the safety position is activated int he supplementary function SIG-ERR or BIN-IN. The safety position set is only moved to when a corresponding signal is present at the binary input (for configuration see BIN-IN), or on occurrence of a signal error (for configuration see SIG-ERR). This function is executed only in the AUTOMATIC mode. ATTENTION!

OPERATION AND CONTROLLER FUNCTIONS SIG-ERR Configuration of error recognition signal level Configure error recognition of setpoint signal Activate signal error recognition Configure error recognition of process value signal Move to safety position if signal in error Move to safety position if signal error When signal error recognition is activated, the error is displayed (see chapter: Maintenance and Error Correction). NOTE 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 (± 0.5 % of end value, hysteresis 0.5 % of end value) Pt100 Error in input signal ≥ 225 °C (± 0.5 % of end value, hysteresis 0.5 % of end value) P1’P2 Error in input signal ≤ 3.5 mA (± 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. INP OFF SPOS OFF ERR INP INP ON SPOS ON ERR END ERR P.INP P.INP ON SPOS ON SIG-ERR P.INP OFF SPOS OFF Activate move to safety position

OPERATION AND CONTROLLER FUNCTIONS BIN-IN Activating the binary input Safety position B.IN SPOS Moving to a safety position. Activated menu item SAFEPOS The actuator moves to the position set under SAFEPOS. Deactivated menu item SAFEPOS The actuator moves to the end position which it would assume in the zero-voltage state. Switching over the operating mode B.IN M / A Switching over the operating mode into MANUAL or AUTOMATIC. Binary input = 0 Operating mode AUTOMATIC Binary input = 1 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. Type of binary input normally closed (0 ... 5 V = 1; 10 ... 30 V = 0) normally open (0 ... 5 V = 0; 10 ... 30 V = 1) BIN-IN Select the function of the binary input Type of binary input B.IN SPOS NORM OPN Safety position NORM CLS NORM OPN NORM CLS B.IN M / A Operating mode changeover

OPERATION AND CONTROLLER FUNCTIONS OUT ANL - Standard signal for the analog position output OUTPUT (Option) Configuration of the outputs NOTE The signal types shown in gray are only selectable with active process controller. Configure the analog output End of configuration of the outputs Configure binary output 2 Configure binary output 1 Current 4..20 mA Current 0..20 mA Voltage 0..10 V Voltage 0..5 V Selection of the desired standard signal Actual position Setpoint position Actual value of process Actual value of process Selection of the desired output

OPERATION AND CONTROLLER FUNCTIONS OUT BIN1 - Configuring binary output 1 Limit position Permissible actuating signal * NOTE NORM CLS (NC) "Normally Closed" output, in switched state low (≅ 0 V) NORM OPN (NO) "Normally Open" output, in switched state high (≅ 24 V)

OPERATION AND CONTROLLER FUNCTIONS ➀ ➀➀ ➀➀ 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. ➁ ➁➁ ➁➁ BIN1 LIM.X Selection: binary position output LIM.X XXX - limit position ➂ ➂➂ ➂➂ BIN1 SPOS Selection: actuator in safety position ④ ④④ ④④ BIN1 SIG Selection: error message setpoint signal ⑤ ⑤⑤ ⑤⑤ BIN1 SIG.P Selection: error message process value signal ⑥ ⑥⑥ ⑥⑥ BIN1 RMOT Selection: operating mode AUTOMATIC and EXTERNAL Setpoint activated OUT BIN1 NORM OPN NORM CLS POS > LIM 0 V 24 V POS < LIM 24 V 0 V OUT BIN1 NORM OPN NORM CLS Operating mode AUTO + External set-value 0 V 24 V Operating mode MANUAL or internal set-value 24 V 0 V

OPERATION AND CONTROLLER FUNCTIONS OUT BIN2 - Configuring binary output 2 Permissible actuating signal * Limit position NOTE NORM CLS (NC) "Normally Closed" output, in switched state low (≅ 0 V) NORM OPN (NO) "Normally Open" output, in switched state high (≅ 24 V)

OPERATION AND CONTROLLER FUNCTIONS OUT BIN2 NORM OPN NORM CLS POS > LIM 0 V 24 V POS < LIM 24 V 0 V ➀ ➀➀ ➀➀ BIN2 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. ➁ ➁➁ ➁➁ BIN2 LIM.X Selection: binary position output LIM.X XXX - limit position ➂ ➂➂ ➂➂ BIN2 SPOS Selection: actuator in safety position ④ ④④ ④④ BIN2 SIG Selection: error message setpoint signal ⑤ ⑤⑤ ⑤⑤ BIN2 SIG.P Selection: error message process value signal ⑥ ⑥⑥ ⑥⑥ BIN2 RMOT Selection: operating mode AUTOMATIC and EXTERNAL Setpoint activated OUT BIN2 NORM OPN NORM CLS Operating mode AUTO + external set-value 0 V 24 V Operating mode MANUAL or internal set-value 24 V 0 V

OPERATION AND CONTROLLER FUNCTIONS 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 NOTE With the removal of the additional function CALUSER, the factory calibration will be re-established.

OPERATION AND CONTROLLER FUNCTIONS ➀ ➀➀ ➀➀ CAL.POS Calibration of the position display (0 - 100 %) 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. ➁ ➁➁ ➁➁ CAL INP Calibration of the position setpoint (4 ... 20 mA; 0 ... 20 mA; 0 ... 5 V; 0 ... 10 V) CAL SP Calibration of the process setpoint (4 ... 20 mA; 0 ... 20 mA; 0 ... 5 V; 0 ... 10 V) 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. ➂ ➂➂ ➂➂ 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. 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 INPUT CAL PV Display of the selection in the menu P.CONTROL / P.CO INP The signal types over a grey background can be selected only with the option flow rate controller.

OPERATION AND CONTROLLER FUNCTIONS + + 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 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 TLIM. + CAL PLIM, CAL TLIM 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 0 ... 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 < 10 % of the sensor measurement range, the zero-point can be balanced, with a pressure > 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 other 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 > 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.

OPERATION AND CONTROLLER FUNCTIONS SETFACT Resetting to the factory settings To initiate the function, hold the MANU- AL/AUTOMATIC key depressed for ca. 5 s until the countdown has finished. 5 s 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.

OPERATION AND CONTROLLER FUNCTIONS 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), 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 modes. Both in the MANUAL and the AUTOMATIC modes, you can change to the configuration 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. 5 sec Operating mode yellow LED in the Display MANUAL/AUTOMATIC key AUTOMATIC flashes An apostrophe (') runs continuously from left to right. MANUAL off -

OPERATION AND CONTROLLER FUNCTIONS 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. Display of the AUTOMATIC mode With regard to the positioner, the following parameters can be displayed: • Actual position of valve actuator POS__XXX (0 ... 100 %) • Setpoint position of valve actuator after rescaling through optionally activated split-range function or correction characteristic: CMD__XXX (0 ... 100 %) • Input signal for setpoint 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. NOTE (yellow LED flashes) In the AUTOMATIC mode, normal controlled operation is executed and monitored. Meaning of the keys in the AUTOMATIC mode: Operating mode AUTOMATIC No operating action AUTOMATIC mode MANUAL mode Release key or (> 5 sec.) Switch over display Menu item Configuration END Switch over the display Change the process setpoint: with configured supplementary functions P.CONTRL / P.CO SETP / SETP INT and display set to SP or or > 3 s

OPERATION AND CONTROLLER FUNCTIONS 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. MANUAL mode Valve closes at normal speed AUTOMATIC mode No operating action release (> 5 sec.) Configuration Menu item Release key Release key Valve closes fast Valve opens at normal speed Valve opens fast release END 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 key in the MANUAL mode: Pressurization of the actuator SFA: valve opens SFB: valve closes SFI: port 2.1 pressurized Press the 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 : Fast pressurization Hold down the key and simultaneously press the : Fast venting NOTE SFA: actuator closing by spring force SFA: actuator opening by spring force SFI: actuator with double action + +

OPERATING THE PROCESS CONTROLLER OPERATING THE PROCESS CONTROLLER Factory settings on the process controller ................................................................................................................................................90 Setting up a process control system ..................................................................................................................................................................90 Self-parametrization for 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

OPERATING THE PROCESS CONTROLLER ➔In all cases, carry out the self-parametrization for positioners (X.TUNE). ➔Via the configuration menu, add the supplementary function P.CONTRL to the main menu. With the function P.CONTRL, the function P.Q'LIN is also inserted into the main menu. ➔Call up the basic settings for the process controller under P.CONTRL. 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 ➔Activate the function P.CO TUNE and initiate self-optimization of the PID parameters of the process controller. Activate valve characteristic curve ➔Initiate the function P.CO KV to activate the valve characteristic. Read in leakage characteristic ➔Initiate automatic determination of the leakage characteristic using the functions P.CO LEAK ➔ P.CO MEAS. Factory settings on the process controller Function Factory setting P.CONTRL P.CO DBND 1 % P.CO PARA KP 1.00 TN 999.9 TV 0.0 X0 0 P.CO SETP SETP INT P.CO INP INP 4´20 A P.CO FILT 0 P.CO SCAL PV 000.0, PV 100.0 P.CO TUNE D’ACT P.CO KV FACT Function Factory setting P.CONTRL with flow rate controller P.CO DBND 1 % P.CO PARA KP 1.0 TN 999.9, TV 0.0 X0 0 P.CO SETP SETP INT P.CO INP INP P1’P2 P.CO FILT 0 P.CO SCAL PV 000.0, PV 100.0, P.TYP FLOW UNIT M3/H, TEMP MAN DENS 1.293, DIAM 0025 P.CO TUNE D’ACT P.CO KV FACT NOTE The functions and factory settings shown in grey are valid for the optional flow rate control. Setting up a process control system ATTENTION! In order to be able to operate the TOP Control Continuous as a process controller, you must execute the following steps: In all cases, keep to the following sequence! X.TUNE ➔ P.Q’LIN ➔ P.CO TUNE

OPERATING THE PROCESS CONTROLLER Self-parametrization of the positioner - X.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 / X.TUNE. Supplementary function P.CONTRL (see also the section „Operating the positioner - configuring the supplementary functions“) Parametrization of the PID controller

OPERATING THE PROCESS CONTROLLER Basic settings of the function P.CONTRL 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 Scaling of the process controller Storage of the new parameters End of the parametrization Filtering of the process actual value input Self-optimization of the process controller (process tune) Parametrization of the process controller kv characteristic curve of process valve Leakage characteristic for flow rate control

OPERATING THE PROCESS CONTROLLER Factory setting: 1% (refers to the span of the process actual value scaled by means of SCAL PV and PV ) This function assures that 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. Entering the dead band in % Insensitivity range with process control P.CO - DBND Insensitivity range (dead band) of the process controller Xd2 Xd2 Xd2' Xd2' to controller Process actual value (PV) Process setpoint (SP) Control difference Dead band

OPERATING THE PROCESS CONTROLLER P.CO - PARA Parameters of the PID process controller P.CO - SETP Type of setpoint setting (internal/external) Gain factor of the process controller 0 ... 99.99 (factory setting 1.00) Operating point 0.0 ... 100 % (factory setting 0 %) Rate time 0 s ... 999.9 s (factory setting 0 s) Reset time 0.5 s ... 999.9 s (factory setting 999.9 s) NOTE For self-optimization of the PID parameters, see Step 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. Setpoint setting internally via the keys on the TOP Control Continuous. Setpoint setting externally via the standard signal input.

OPERATING THE PROCESS CONTROLLER P.CO - INP Specification of the signal type for process actual value Frequency signal (flow rate) 0 ... 1000 Hz Connection with Pt100 (temperature) - 20 °C ... + 220 °C Configuration for flow rate controller - option standard signal current 4 ... 20 mA (flow rate, pressure, level) Setting in 10 steps P.CO - FILT Filtering of the process actual value input FILT XX Setting in 10 steps: 0 ... 9 Valid for all types of process actual value. Filter has low-pass behavior (PT1). Range: 0 ... 9 Factory setting: 0 Setting Corresponds to limiting frequency (Hz) Effect 0 10 minimum filtering 1 5 2 2 3 1 4 0.5 5 0.2 6 0.1 7 0.07 8 0.05 9 0.03 maximum filtering

OPERATING THE PROCESS CONTROLLER P.CO SCAL Scaling the process controller on selection of analog input 4 ... 20 mA (P.CO INP 4 - 20 A) 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 smallest 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 is only active when P.CO SETP / SETP EXT is selected. (*) This setting determines the reference span for the dead-band of the process controller and the analog feedback of the process actual value (option). XX.XX XX.XX XX.XX XX.XX

OPERATING THE PROCESS CONTROLLER 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 Example of scaling for 4 ... 20 mA input: NOTE 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 P.CO SETP / SETP INT (setpoint entry via the arrow keys), scaling of the setpoint via SP and SP is not possible. The setpoint may be entered directly corresponding to the scaled process variable (PV , PV ). Process actual value Scaling value [l/min] Process setpoint Input signal [mA] Variant 1 Variant 2 Variant 3 PV 0 0 0 PV 1.0 10.0 100.0 SP 0 0 0 SP 0.8 8.0 80.0 Example for entering scaling values

OPERATING THE PROCESS CONTROLLER P.CO SCAL Scaling the process controller on selection of the frequency input (P.CO INP FREQ) Unit l/s Unit l/min Unit m³/min Unit m³/h Unit gal(US)/s Unit gal(US)/min Unit gal(US)/h Unit gal(Imperial)/s Unit gal(Imperial)/min Unit gal(Imperial)/h NOTE 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.