TOPCONTROL CONTINUOUS TYPE 8630

CONTENTS:
1 GENERAL INFORMATION ....................................................................................... 87
1.1 Symbols ................................................................................................................................................. 87

1.2 Safety information ................................................................................................................................. 87

1.3 Important for Handling ......................................................................................................................... 87

1.4 Scope of delivery .................................................................................................................................. 87

1.5 Warranty conditions .............................................................................................................................. 88

1.6 Master code ........................................................................................................................................... 88

2 SYSTEM CONFIGURATION ..................................................................................... 89

3 DESCRIPTION OF THE TOPCONTROL CONTINUOUS ......................................... 91
3.1 Construction .......................................................................................................................................... 91

3.2 Function ................................................................................................................................................. 93

3.2.1 Working as position controller ................................................................................................................. 94
3.2.2 Using as process controller ..................................................................................................................... 95
3.3 TopControl variants ............................................................................................................................... 96

3.4 Software characteristics........................................................................................................................ 97

3.5 Technical characteristics ...................................................................................................................... 98

3.5.1 Safety positions according to electrical and pneumatic power supplys................................................... 98
3.5.2 Factory settings of the TopControl Continuous ........................................................................................ 99
3.5.3 Characteristics of the TopControl Continuous ........................................................................................ 100
4 INITIAL COMMISSIONING ...................................................................................... 101
4.1 Pneumatic connection ........................................................................................................................ 101

4.2 Electrical connection .......................................................................................................................... 101

4.2.1 Multipol connection ............................................................................................................................... 101
4.2.2 Cable gland connection ......................................................................................................................... 102
4.2.3 QUICKON connections .......................................................................................................................... 103
4.3 Basic configuration ............................................................................................................................. 103

5 INSTALLATION ....................................................................................................... 107

5.1 Installation of the valve ....................................................................................................................... 107

5.2 Turning the TopControl Continuous .................................................................................................. 107

5.3 Pneumatic connection of the TopControl Continuous ....................................................108
5.4 Electrical connection .......................................................................................................................... 108
5.4.1 Multipole connection ............................................................................................................................. 109
5.4.2 Cable gland connection ......................................................................................................................... 111
5.4.3 QUICKON connections .......................................................................................................................... 113
5.3 Adjusting the inductive proximity switch (option) ........................................................................... 116

TopControl Continuous 85
6 OPERATION ............................................................................................................ 117
6.1 Control and display elements ............................................................................................................ 117

6.2 Operating levels .................................................................................................................................. 117

6.3 Commissioning as a position controller........................................................................................... 118

6.3.1 Basic configuration ................................................................................................................................ 118
6.3.2 Operating mode for basic configuration ................................................................................................. 118
6.4 Configuration of the additional functions ......................................................................................... 122
6.4.1 Keys in the configuration menu ............................................................................................................. 122
6.4.2 Configuration menu ............................................................................................................................... 122
6.4.3 Additional functions ............................................................................................................................... 124
6.5 Setting a process control function .................................................................................................... 145
6.5.1 Starting the function to obtain linear characteristic curve ..................................................................... 145
6.6 Process operation level ...................................................................................................................... 146
6.6.1 AUTOMATIC operating mode ................................................................................................................. 146
6.6.2 MANUAL operating mode ...................................................................................................................... 149
7 FAILURES AND REPORT ERRORS..................................................................... 151
7.1 Report errors on LCD display ............................................................................................................. 151

7.2 Miscellaneous failures ........................................................................................................................ 151

APPENDIX A ....................................................................................................................... 153

Selection criteria for continuous valves ........................................................................................................... 153

Characteristics of PID controllers ..................................................................................................................... 155

Rules for adjusting PID controllers .................................................................................................................. 159

APPENDIX B ....................................................................................................................... 161

Operating structure of the TopControl .............................................................................................................. 161

APPENDIX C ....................................................................................................................... 161

Tables for your settings ..................................................................................................................................... 165

FUNCTIONS OF THE TOPCONTROL CONTINUOUS

Function Page Function Page
Actfunc 120 P.control 132
Input 120 P.co - dbnd 132
Addfunct 120 P.co - para 133
END 121 P.co - setp 134
X.tune 121 P.co - inp 134
Charact 125 P.co - filt 134
Dir.cmd 127 P.CO SCAL 135
Cutoff 127 CODE 138
Dir.act 128 Output 139
SPLtrng 129 BIN-IN 139
X.limit 130 cal.user 141
X.time 130 setfact 144
X.control 131 P.Q’LIN 145

86 Operating instructions no. 800607

1 GENERAL INFORMATION

1.1 Symbols

The following symbols are used in these operating instructions:

indicates a working step which must be performed

ATTENTION!
Indicates information, which if not observed can result in harmful effects on the health or the serviceability of
the unit.

NOTE Indicates important additional information, tips and recommendations.

1.2 Safety information

Please observe the information in these operating instructions, as well as the operating conditions and permissible data specified
in the date sheets of the TopControl and of the relevant pneumatically actuated valve, to ensure satisfactory operation of the unit
and a long service life:

• Follow general technical rules when planning the application and operation of the unit!

• Installation and maintenance may only be performed by technical personnel provided with suitable tools!

• Note the accident prevention and safety precautions applicable for electrical units during operation and maintenance of the
unit!

• Always switch off the power supply before working on the system!

• Take suitable measures to prevent inadvertent operation or impermissible influences!

• Ensure a defined and controlled re-start of the process following an interruption of the electrical or pneumatic supply!

• We cannot accept any liability if these instructions are ignored or impermissible interventions are made in the unit and the
warranty also becomes invalid on units and accessories!

1.3 Important for Handling

This electronic device is sensitive to electrostatic discharge (ESD). Contact with an

electrostatic charged person or object endangers the electronic device. The worst case
is that it will be destroyed immediately or just fail after putting into operation.
To minimize the possibility of damage by immediate electrostatic discharge, pay
attention to the requirements of EN 100 015 -1. Please also pay attention not to
assemble the electronic device while supply voltage is put on.

ATTENTION
OBSERVE PRECAUTIONS
FOR HANDLING !
ELECTROSTATIC
SENSITIVE
DEVICES

TopControl Continuous 87
1.4 Scope of delivery

Check the contents of the delivery for damage and agreement with the details specified on the delivery note immediately
following receipt. This normally comprises:

• pneumatically actuated valve of types 2652, 2655, 2672, 2700, 2712, 2730, 2731 or 2731K with the TopControl Continuous

• operating instructions for the valve with pneumatic drive

• operating instructions for the TopControl Continuous

Suitable cable plugs for the multipole connection are available as accessories.

In the event of discrepancies, please contact our service department immediately:

Bürkert Steuer- und Regelungstechnik

Chr.-Bürkert-Str. 13-17
Service-Abteilung
D-76453 Ingelfingen
Tel.: (07940) 10-252
Fax: (07940) 10-428

or your local Bürkert branch.

1.5 Warranty conditions

This document contains no warranty promises. We refer in this connection to our General Conditions of Sale and Business. The
condition for the warranty is use of the unit for the intended purpose under the specified application conditions.

ATTENTION!
The guarantee only covers faults in the TopControl Continuous, and in the integrated pneumatically-driven
valve. No liability will, however, be accepted for subsequent damage of any kind that may arise as a result of
the failure or incorrect functioning of the device.

1.6 Master code

Operation of the device can be locked via a freely selectable user code. Independent of this, there is an unalterable master
code with which you can carry out all operations on the device. This 4-digit master code is printed on the last page of these
operating instructions.

If needed you can cut out this code and store it separately from these operating instructions.

88 Operating instructions no. 800607

2 SYSTEM CONFIGURATION

NOTE The following picture illustrates a complete system, based on

• a control valve with a pneumatic actuator
• a TopControl Continuous
These elements linked together compose a functional unit.

The function ranges of the Bürkert pneumatic control valves are greatly increased when in combination with the TopControl
Continuous. These valves can be fitted with the TopControl Continuous in order to obtain continuous control with variable
functions.

The figure 2.1 below shows various combination capabilities of the TopControl Continuous combined with various pneumatic
control valves. A vast range of connections and valve diameters is available, although not displayed in the figure below. All
technical informations about these products are described in the relevant data sheets. The product range will be continuously
increased.

TopControl
Type 8630

with flat seat valve Type 2712 with slanted seat with diaphragm valve
(here with flange connection) valve Type 2700 Type 2730

Top Control
Type 8630

with ball valve Type 2655

with swing valve Type 2672

Fig. 2.1: Overview of mounting options for the Top Control Continuous with various valve types

TopControl Continuous 89
Various control valves from the Bürkert range may be used in connection with the Top Control Continuous depending on the installation
conditions. Angle valves, diaphragm valves, including ball valves fitted with a control cone are suitable, as well as piston or rotary driven
pneumatic actuators.

Pneumatic piston actuators or rotary actuators may be used as actuators. Single acting and double acting actuators may be used in
combination with the TopControl.

Within a single action actuator a single chamber is filled and exhausted. The resulting pressure acts on a spring, which forces the piston
to move until the pressure difference between the piston and spring are equal.
Double chamber actuators posses 2 chambers, which supply the pressure to the piston. The filling of one chamber induces the emptying
of the other, as there is no spring within this design.

Valves characteristics:

Flat seat control valves Diaphragm valves Ball valves

Slanted seat control valve

Types • 2700 • 2730 • 2652 (2 parts)

• 2712 • 2731 • 2655 (3 parts)

• 2731K

Characte- • flow over under the seat • fluid tightly isolated from the actuator and environtment • possibility of internal scraping
ristics
• protected against water hammer • no dead volume, self purging design • reduced dead volume

• straight flow direction • direction of flow as required with minimal turbulence of • low retention of deposits
flow
• high tightness through selfpositioning • replaceable seat and seals through 3 parts ball
packing box • steam sterilizable valve design

• CIP

• water hammer free

• removable diaphragm and actuator through mounted

housing

Typical • water, steam and gas • neutral fluid and gas • neutral fluid and gas
medium
• alcohol, oil, fuel, hydraulic fluids • charged or aggressive fluids • pure water

• brine, organic fluids, base • high purity or sterilised fluid • low aggressive fluids

• solvent • high viscosity fluids

90 Operating instructions no. 800607

3 DESCRIPTION OF THE TOPCONTROL

The type 8630 TopControl Continuous is an electropneumatic position controller for pneumatically actuated continuous valves.
The TopControl Continuous and pneumatic actuator are joined together to build one functional unit.

3.1 Construction

The design of the type 8630 TopControl Continuous (Fig. 3.1) is based on a modular concept.
Wide ranges of pneumatic and electrical connections are available as options.

Screw adjustment for the lower

approximate switch
Screw adjustment for the
upper approximate switch
Position controller
with 2, 3 or 4
solenoid valves

Control unit with

display and keypad

Pressure supply
connection
(Marked: 1)

Air command Exhaust air

connection (Marked: 3)
(closed on working
side)

Electrical connection module

with QUICKON connectors

Fig. 3.1: Design of the TopControl, cover removed

TopControl Continuous 91
 CONSTRUCTION FEATURES:

• Design:

for single/double-acting actuators

• Path measuring system:

high linear resolution with plastic potentiometer. Freely

coupled to the piston rod of the actuator

• Electronic system piloted by a microprocessor:

ensure an efficient configuration, control, and drive of the

actuator

• Control unit:

Operation of the TopControl by mean of 3 keys.

An 8 character LCD ensures the display of setpoint, position,
and configuration functions.
Fig. 3.2: Electrical connection
• Positioning system:

The positioning system is composed and requires 2 solenoid valves for single-acting actuators (air inlet; exhaust air), or 4
solenoid valves for double-acting actuators (2 for air inlet; 2 for exhaust air).
The controller with a PWM-voltage powers the valves according to the rocker principle which allows fast positioning volumes
to be reached as required.
A large flexibility concerning the volumes of the chambers and the positioning speed is reached in that way. For use of
actuators with larger volumes, the positioning valves are fitted with membrane amplifiers in order to increase the maximal flow
and optimise the dynamic of the system.

As an option with single-acting actuators, a fast pressurizing/venting version is available with an additional pressurizing
valve and venting valve. This enables the actuator to be completely pressurized and vented more rapidly. This is used with
the tight-closing function (see chapter "CUTOFF") and on activating a safety position of 0 or 100% (see chapter "BIN-IN").

• Position indicator (option):

2 inductive approximate value switches (capacitive

switches) or mechanical limit switches. Signalling the high or
low limit positions of the actuator by a digital output or via a
PLC. Positioning screws allow free adjustment of the limit.

• Electrical connection (Fig. 3.2):

Multipole connector, cable glands with terminals, or

QUICKON box connection.

• Pneumatic connection (Fig. 3.3):

1/4’’ connection brass or stainless steel

with various connection types (G, NPT, RC)

Fig. 3.3: Pneumatic connection

• TopControl Continuous body:

Protected against internal over-pressure, (eg. air leakage) by a pressure limit valve.
Protection against non-authorised opening of the cover by a seal or self-cutting screws.

92 Operating instructions no. 800607

3.2 Function

The figure 3.4 shows the functional diagram of the TopControl Continuous in combination with a single acting piston valve.

Process value

Process
setpoint Position
Process
controller setpoint
external
position
setpoint
Position
Actuator
controler
1: Air inlet valve
Position 2: Air exhaust valve
feedback
Actuator
TopControl
Pressure air inlet
Displacement
measurement
system

Air exhaust

Pneumatic actuator
(single acting)

Control valve
(Control output)

Sensor

Process value
(Flow, pressure, level,
temperature, ...)

Fig. 3.4: Functional diagram of the TopControl Continuous in combination with a single acting piston valve

TopControl Continuous 93
 Fig. 3.5: Process control example: TopControl with sensor

3.2.1 Working of the TopControl Continuous as position controller (Fig. 3.6)

The actual position (POS) is measured by the displacement measuring system. This position value is compared to the normalized
position setpoint signal (CMD). In cases of difference (Xd1), a voltage pulse-width modulation signal is sent as control signal.
With single-acting actuators, a positive error exists and pulses are sent from output B1 to activate the air supply. When a negative
error exists, and pulses are sent from output E1 to activate the exhaust air. With this system, the difference between the position
of the actuator and the setpoint is reduced 0. Z1 represents a disturbance variable.

Z1

B1
CMD Xd1 PK Valve opening
E1

Position Position controller Position Valve actuator

setpoint conctrol sole-
noid valve

POS

Path measuring system

Position control

Fig 3.6: Position control diagram

94 Operating instructions no. 800607

3.2.2 Using the TopControl Continuous as a process controller (Fig. 3.7)

By using the TopControl Continuous as a process controller, the previous position control function is a component of the main
control loop.
The process controller within the main control loop posseses a PID function. The process setpoint (SP) is used and compared to
the controlled process value (PV). A sensor delivers the actual value. The manipulated variable correction functions as described
in chapter 3.2.1 represents a disturbance variable.

Z1

B1
Xd1 PK Valve opening
E1

Position controller Position Valve actuator

control soleno-
id valve

XPOS

Path measuring system

Position control

Z2

Valve
CMD Position Process value
SP Xd2 opening
control
loop
Process setpoint Process controller soleno- Process
id valve

PV

Transmitter

Fig 3.7: Process control diagram

TopControl Continuous 95
3.3 TopControl Continuous variants

The TopControl Continuous is available in 3 forms, varying in electrical connection and control functions.

• Multipole connection with complete functions (Fig. 3.8)

• Terminal with PG cable glands and terminals with restricted functions (Fig. 3.9)

• QUICKON connection with restricted functions

External setpoint for posi- 2 binary output

tion or process control
4..20 mA
0..20 mA Analogue position feedback
0..10 V
0..5 V

Process control value Limit switch 1 + 2

4..20 mA TopControl
Input

Output
Frequency
Pt 100 Continuous
(Multipole
Binary input connection)
supply
Power

24 V DC
Pt 100

Operating

Fig. 3.8: Position interface with multipole connections

External setpoint for posi- 2 binary output

tion or process control (as an alternative to input for
4..20 mA process set value)
0..20 mA
0..10 V
0..5 V

TopControl Analogue position feedback

Process control value
Input

4..20 mA Continuous
Output

Frequency
Pt 100
(as an alternative to binary
(PG and QUICKON
outputs) variants)
supply
Power

24 V DC

Operating Advice:
Choose between an analogue
position feedback and two binary
outputs by setting the jumper.

Fig. 3.9: Interfaces of the TopControl Continuous on the variants with PG screw connectors and QUICKON connectors

NOTE The TopControl Continuous posses 3-wires instruments. The 24 V DC power supply is isolated from the setpoint
signal.

96 Operating instructions no. 800607

3.4 Software characteristics

Additional function Operation

Positon controller with additional functions

Close tight function Valve tightly closed over the tightness process range
Statement of a value (in %) above which the drive is completely de-aerated
(at 0 %) or ventilated (at 100 %)

Plug travel limitation Mechanical movement of the valve piston within a specified stroke range

Split range The signal is split in 2 or more positions

Characteristics curves for process The linearization of the characteristic curvecan be processed
value adjustment

Deadband The TopControl acts only if a specified control difference is measured

Direction of command of nominal and actual Relationship between the setpoint limit values and the position of the actuator
value

Safety position The valve moves to a specified safety position

Automatic adjustment to the connected valve

Connections of the process controller with the following functions

Control type PID

Available parameters Proportional coefficient, reset time, action rate and operating point

Input scale Position of the decimal point, lower and upper scale values of the actual value
and setpoint

Selection of the setpoint entry mode Setpoint entry manual or external

Automatic adjustment to the conditions of the process

Hierarchical concept for easy commissioning with the following levels:

Process mode Selection between automatic and manual modes

Configuration mode Selection of the basic functions, and if necessary additional functions within
this level

TopControl Continuous 97
3.5 Technical characteristics

3.5.1 Safety positions according to electrical and pneumatic power supplys

Type of actuator Designation Safety settings following failure

or auxillary power supply

electrical pneumatic

single acting down down

WW A

single acting up up
WW B

double acting down / up not assigned

WW I (depending on con-
nection of control
lines)

98 Operating instructions no. 800607

3.5.2 Factory settings of the TopControl Continuous

Function Factory setting Function Factory setting

Actfunc funcsngl X.control 1%

Input Inp 4'20A P.co - dbnd 1%

Charact Cha lin P.co - setp setp int

Dir.cmd DIR.crise P.co - inp Inp 4'20A

Cutoff CUT = 1 %; CUT = 99% P.CO - FILT 0

Dir.act DIR.Arise P.co - scal unit l/s

SPLtrng SR = 0 (%); SR = 100 (%) CODE CODE 0000

X.limit LIM = 0%, LIM = 100% Output out 4'20A

X.time no limitation BIN-IN Inp 4'20A

TopControl Continuous 99
3.5.3 Characteristics of the TopControl Continuous
Operating data

Operating temperature 0...+50°C

Degree of protection IP 65 according to EN 60529

(in correct electrical installation conditions)

Conformity to norms

CE According to CE 89/336

Mechanical data

Dimensions refer to data sheet

Material of the body external POM, PSU

internal PA 6

Material of the seal NBR

Electrical data

Connections multipole connectors,

terminal with two PG 9 screwed glands or
QUICKON connection (see fig. 5.2)

Power supply 24 V DC ± 10 %
Residual pulsation 10 %
No technical direct voltage!

Power consumption <5W

Input resistance for actual signal 180 Ω at 4 - 20 mA

17 kΩ at frequency

Input resistance for set-point signal 180 Ω at 0/4 - 20 mA

19 kΩ at 0 - 5/10 V

Protection class 3 according to VDE 0580

Analog position feedback:

Max. current for voltage output 0...5/10 V 10 mA
Max. burden for current output 0/4 mA 560 Ω

Inductive proximity switch:

Current limitation 100 mA

Binary outputs:
Current limitation 100 mA

Pneumatic data

Control medium instrument air, class 3 according to DIN ISO 8573-1

Compressed air temperature -20°C

Oil content max. 1 mg/m³

Dust content 5 µm filtered

Temperature of the pressure air 0..+50°C

Pressure range 3..7 bar 1)

2)
Pressure fluctuations max. ± 10 % during service

Airflow rates Steuerventile 100 lN /min (for air supply and exhaust) 3)
(QNn-Value according to definition of the pressure loss from 7 to 6 bar absolute)

Union connections G / NPT / RC 1/4’’ internal thread

1)
The control pressure has to exceed the pressure from 0.5- 1 bar, in order to ensure the final positioning of the actuator.
2)
Higher pulsation reduces the control accuracy based on the autotune function.
3)
We reserve the right to make technical changes to optimize the function of the TopControl.

100 Operating instructions no. 800607

4 INITIAL COMMISSIONING

NOTE This section allows you to perform the quick commissioning of the TopControl Continuous. The not essenti-
al additional functions are not described in this section. See chapter 5 and 6 for complete explanations
about commissioning and the functions available.

4.1 Pneumatic connection

➔ Install the valve according to the specific requirements.

➔ Connect the air supply (3..7 bar, instrument air, oil, water and duster) to port 1.

➔ Mount the exhaust air pipe or noise reducer on port 3.

M16 M12

4.2 Electrical connection

4.2.1 Multipole connection

➔ Connect the external position setpoint signal to the
circular connector M16.

Fig. 4.1: TopControl with multipole connectors

Connection of the circular connector M16:

Pin Assignment External connection

B Setpoint + (0/4..20 mA) B + (0/4..20 mA) or 0..5 / 10V

or
0..5 / 10V A GND
A Setpoint GND

➔ Connect the power supply to the circular connector M12.

Connection of the circular connector M12 :

Pin Assignment External connection

1 + 24 V
1
2 not connected 24 V DC ± 10 %
Residual ripple 10 %
3 GND
3
4 not connected

TopControl Continuous 101

4.2.2 Cable gland connection

Easy connection of the terminal box:

➔ Remove the 4 self-cutting screws to open the cover of

the terminal box.
The connections of the terminals are shown in figure
4.2. Terminals

➔ Connect the external position setpoint signal and

power supply wires to the terminals (according to the
PG-terminal assignment).

Fig. 4.2: TopControl Terminals

Connection of terminals (with cable glands)

Terminal Assignment External connection

1 Setpoint + 1 + (0/4..20 mA or 0..5 / 10V)

2 Setpoint GND 2 GND

5 Power supply + 5
24 V DC ± 10 %
Residual ripple 10 %
6 Power supply GND
6

NOTE Further installation procedure, see chapter 5.

Once activated, the TopControl Continuous will work and the necessary configuration and self-calibration operations of the
TopControl Continuous will have to be performed (Fig. 4.4).

102 Operating instructions no. 800607

4.2.3
4.2.3 QUICKON connectors

QUICKON Pg9, 3-pole

Fig. 4.3:
QUICKON connectors on QUICKON Pg11, 4-pole
TopControl

Lay the set-point signal on the QUICKON connector PG11, 4-pole:

Pin Assignment External connection

3 Set-point GND 4 + (0/4..20 mA or 0..5 / 10V)

4 Set-point +
3 GND

Lay the supply voltage on the QUICKON connector PG9, 3-pole:

Pin Assignment External connection

1 Operating voltage +24 V 1

24 V DC ± 10 %
2 Operating voltage GND max. residual ripple 10 %
2

4.3 Basic configuration

Key assignment:

MANUAL/AUTOMATIC key Choice of menu and sub-menu

e. g. ACT FUNC - FUNCSNGL

ARROW key Choice between level menu

functions
e.g. ACTFUNC - INPUT

Fig. 4.4 Key on TopControl

TopControl Continuous 103

 AUTOMATIC
Mode 5s

MANUAL
Mode

Omit during first commissioning

5s

Fig. 4.5: Basic configuration

104 Operating instructions no. 800607

 Configuration within the MAIN menu:

ACTFUNC Function of the actuator

FUNC SNGL - single acting

FUNC DOUB - double acting

INPUT Selection of the input 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 Omit for quick commissioning

X.TUNE Activation of the self-calibration (Fig. 4.4).

END xx Return to the AUTOMATIC mode. The message EEPROM is displayed until the new
parameters are stored.

TopControl Continuous 105

 Entry of the setpoint within the AUTOMATIC mode

After the configuration the TopControl acts as a position controller.

➔ Enter the setpoint as a signal input.

➔ Switch between the display possibilities:

Message on display:

• Actual position of the actuator POS__xxx (0..100%)

• Setpoint of the actuator CMD__xxx (0..100%)

• Signal entry for the setpoint

(equivalent to setpoint) INP__xxx (0..100%)

• Internal temperature of the TopControl TEMP_xx.x (in °C)

Manual opening and closing of the valve within the MANUAL mode

Open the valveantriebs:

Close the valveantriebs:

Message on display: The previous display within the AUTOMATIC mode remains active.

NOTE Advice Select the POS_xxx display, to ensure that the actual position of the actuator is displayed.

106 Operating instructions no. 800607

5 INSTALLATION

Please refer to the data sheets for dimensions of the TopControl Continuous and complete instrument variants of the
TopControl, pneumatic actuators and valves.

5.1 Installation of the valve

NOTE The actuator must not be connected.

For dimensions and thread types, see data sheet of process valve.

5.2 Turning the TopControl Continuous

If after installation of the continuous valve, the display of the TopControl Continuous is poorly visible or the cables or hoses
are difficult to connect, the TopControl Continuous can be turned relative to the pneumatic actuator.

The procedure is as follows:

Loosen the fluidic connection between the TopControl Continuous and the pneumatic actuator.

Loosen the grub screw sunk in the side of the housing (hex socket SW3).

Turn the TopControl Continuous clockwise, without lifting, into the desired position.

Retighten the grub screw with a moderate torque.

Remake the fluidic connection between theTopControl Continuous and the pneumatic actuator.
If necessary, use longer hoses.

ATTENTION!
If the TopControl Continuous is lifted on turning (displaced axially), the mechanically coupling of the
distance measuring system may be damaged. By turning in the wrong direction (anticlockwise), there is a
risk of unhooking the distance measuring system. It can only be hooked in again with a special tool!

TopControl Continuous 107

5.3 Pneumatic connection of the TopControl Continuous

➔ Connect the air supply (3..7 bar, instrument air, oil, water and duster) to port 1 (Fig. 5.1).

➔ Mount the exhaust air pipe or noise reducer on port 3 (Fig. 5.1).

Supply pressure
connector (inscription: 1)

Outlet air connector

(inscription: 3)

Bild 5.1: Fluidic connections of the TopControl

NOTE The pressure supply must exceed the pressure required by the pneumatic actuator and must exceed at
least 0.5 to 1 bar.
This is to ensure that the control process in the upper ranges of the actuator will not become negative due
to a lower pressure difference.

Keep the pressure supply variations within the most restricted limits (max. ±10 %).
Higher variations reduce the reliability of the measured parameters within the AUTOTUNE procedure.

5.4 Electrical connection

Various options are available for electrical connection

• Multipole connection

• Terminals (with cable glands)

• QUICKON connection

ATTENTION!
A screw with a nut is available in the connecting module for connection of the technical earth (TE). In
order to comply with the EMC requirements connect this screw to a good earthing point with a short
length cable (max. 30 cm).

108 Operating instructions no. 800607

5.4.1 Multipole connection

The figure 5.2 indicates the functions of the multipole connectors and assignment of the pins.

Power supply
Signal to SPS

M16 M12

M8 M8

Initiators
Process value

Fig 5.2: Circular connector with pin assignment

Output signal to SPS (circular connector M16)

Pin Assignment External connection

A Setpoint GND B + (0/4..20 mA or 0..5 / 10V)

(completely separated galvanically)
B Setpoint + (0/4..20 mA or 0..5/10 V)
A GND
C Analogue position indication + C + (0/4..20 mA or 0..5 / 10V)
(completely separated galvanically)
D Analogue position indication GND D GND

E Binary output 1 E 24 V / 0 V
F 24 V / 0 V
F Binary output 2

G Binary output GND G GND

H Binary input + H + 0..5V (log. 0)

J 10..30 V (log. 1)
J Binary input GND GND

K not connected

L not connected

M not connected

TopControl Continuous 109

 Power supply (circular connector M12)

Pin Assignment External connection

1 + 24 V

2 not connected 24 V DC ± 10 %
Residual ripple 10 %
3 GND

4 not connected

Inductive proximity switch (circular connector M8)

Pin Assignment External connection

S1
1 Proximity switch 1 + (NO) 1
+24 V DC open / 24 V
2
2 Proximity switch 1 GND GND GND

3 Proximity switch 2 + (NO) S2

3
+24 V DC open / 24 V
4 Proximity switch 2 GND 4
GND GND

Process value (circular connector M8)

Signal * Pin Assignment Jumper External connection

4..20 mA 1 + 24 V transmitter entry

- internal power 2 Transmitter output
supply 3 GND Transmitter
4 Strap to GND

4..20 mA 1 not connected

- external power 2 Analogic signal +
supply 3 not connected
4 Analogic signal -

Frequency 1 +24 V supply of sensor 1 +24 V

-internal power 2 Pulse + 2 Puls +
supply 3 Pulse -
4 not connected 3 Puls -

Frequency 1 not connected Puls +

2
-external power 2 Pulse +
supply 3 Pulse - 3 Puls -
4 not connected

Pt-100 1 not connected 3

2 Process 1 4
3 Process 3 Pt 100
4 Process 2
2

* Connectable through software (see 6.3.2)

110 Operating instructions no. 800607

5.4.2 Cable gland connection

Easy connection of the terminal box:

Remove the 4 self-cutting screws to open the cover of the terminal box.
The disposal of the terminal is shown on figure 5.3.

Straps

Terminals

Fig. 5.3: TopControl terminals and straps

Connection of terminals (with cable glands)

Terminal Assignment External connection

1 Setpoint + 1 + 0/4..20 mA or 0..5 / 10V

2 Setpoint GND 2 GND

3 Analogic position feedback + 3 + 0/4..20 mA oder 0..5 / 10V

(completely separated galvanically)
4 Analogic position feedback GND 4 GND

5 Power supply + 5
24 V DC ± 10 %
Residual ripple 10 %
6 Power supply GND
6

TopControl Continuous 111

 Selection between digital output and process value input:

Select using the strap:

- 2 digital outputs (see terminal assignment when digital output selected)

or
- process value inputs (see terminal assignment when process value is selected).

The terminals 7 to 10 are connected to the corresponding signals.

Connect the limit switches to the terminals:

Strap Terminal Assignment External connection

7 Digital output 1 7 24 V / 0V

8 Digital output 1
8 GND

9 Digital output 2 9 24 V / 0V

10 Digital output 2
10 GND

Connection of the process value to the terminals:

Set the type of entry signal within the configuration menu (see 6.3.2).

Signal Strap Terminal Assignment External connection

4..20 mA 7 +24 V transmitter entry 7

+ 24 V
internal
power supply 8 Transmitter output 8 Transmitter

9 GND
9
10 GND
10
GND

Frequency 7 +24 V power supply 7 +24 V

internal
power supply 8 Pulse + 8 Pulse +
10 Pulse -
9 not connected

10 Pulse -

4..20 mA 7 not connected

external
power supply 8 Analogic signal + 8 + (4..20 mA) V

9 not connected GND

10
10 Analogic signal -

Frequency 7 not connected

external Pulse +
8
power supply 8 Pulse +

9 not connected Pulse -

10
10 Pulse -

Pt-100 7 not connected 10

8 Process 1 9

Pt-100
9 Process 2
8
10 Process 3

112 Operating instructions no. 800607

5.4.3 QUICKON connectors
QUICKON PG9, 3-pole

TE
QUICKON Pg11, (Technical QUICKON Pg11,
Fig. 5.4: QUICKON connectors on 4-pole Earth) 4-pole
TopControl

QUICKON connector PG9, 3-pole:

Pin Assignment External connection

1 Operating voltage +24 V 1

24 V DC ± 10 %
2 Operating voltage GND Residual ripple 10 %
2
3 not connected

QUICKON connector PG11, 4-pole:

Pin Assignment External connection

1 Analog position transmitter GND 2 + 0/4..20 mA or 0..5 / 10V)

(completely separated galvanically
2 Analog position transmitter +
1 GND

4 + (0/4..20 mA or 0..5 / 10V)

3 Set-point GND

4 Set-point + 3 GND

QUICKON connector PG11, 4-pole:

Choice between binary outputs and process actual value input:

Select via jumpers

a) 2 binary ouputs (see pin assignment on choice of binary ouputs)

or

b) Process actual value input (see pin assignment on choice of process actual value input)

TopControl Continuous 113

 a) Pin assignment on selection of the binary outputs

Jumper QUICKON pin Assignment External connection

1 24 V / 0V
1 Binary output 1+

2 Binary output 1- 2 GND

3 Binary output 2+ 24 V / 0V
3
4 Binary output 2-
4 GND

b) Pin assignment on selection of the process actual value input

The input type is set via the configuration menu (see 6.3.2).

Input type Jumper Pin Assignment External connection

4..20 mA 1 +24 V input transmitter 1

+ 24 V
supplied
internally 2 output transmitter 2 Transmitter

3 GND
3
4 GND
4
GND

Frequency 1 +24 V supply sensor

supplied 1 +24 V
internally 2 Clock input +
2 Clock input +
3 not connected
4 Clock input - (GND)
4 Clock input - (GND)

4..20 mA 1 not connected

supplied
externally 2 Process actual + 2 + (4..20 mA) V

3 Process actual - GND

3
4 not connected

Frequency 1 not connected

supplied
externally 2 Clock input + 2 Clock input +

3 not connected Clock input -

4
4 Clock input -

Pt-100 1 not connected 4

2 Process actual 1 3

3 Process actual 2 Pt-100

4 Process actual 3 2

114 Operating instructions no. 800607

 Information on connecting the QUICKON connectors to cable

QUICKON PG9 / 3-pole

Range of wire cross-sections 0.34..0.75 mm²

Strand structure / smallest diameter VDE 0295 Class 2 to 5 / 0.2

Wire insolation material PVC / PE

Outside diameter of conductors 4...6 mm

Wire diameter (incl. insolation) ≤ 2.5 mm

Rated voltage 160 V

with overvoltage category / degree of contamination III / 3

QUICKON PG11, 4-polig

Range of wire cross-sections 0.34..0.75 mm²

Strand structure / smallest diameter VDE 0295 Class 2 to 5 / 0.2

Aderisolationsmaterial PVC / PE

Outside diameter of conductors 4...7.5 mm

Wire diameter (incl. insolation) ≤ 2,5 mm

Rated voltage 160 V

with overvoltage category / degree of contamination III / 2

TopControl Continuous 115

5.5 Adjusting the inductive proximity switch (option)

ATTENTION!
It is necessary to open the TopControl housing to install the inductive proximity switch.
Disconnect the power supply before opening open the TopControl.

Opening the TopControl :

➔ Remove the screws and possible seals between the cover and the housing.

➔ Twist the cover to the left and remove it.

Installing the inductive proximity switch:

➔ Mount each inductive proximity switch at the top over the fixing screws. (Fig. 5.4):

Turn right ensures Turn left ensures

adjustment adjustment
to the top to the top

Fixing for upper position

switch
Fixing for lower position
switch

Bild 5.5: Setting of the inductive proximity switch with the setscrews

116 Operating instructions no. 800607

6 OPERATION

6.1 Control and display elements

The TopControl Continuous has 3 keys and a LCD (Fig 6.1).

The functions of the keys are described in the following section.

Arrow up key MANUAL/AUTOMATIC key

LED
(in the MANUAL/
AUTOMATIC key)

Arrow down key

Fig. 6.1: Control and display elements

6.2 Operating levels

2 operating levels are provided for operation of the TopControl Continuous (fig. 6.2):

• Process operation level:

This level is automatically set each time the unit is switched on. It allows changing between the MANUAL and AUTOMATIC
operating modes. In the AUTOMATIC mode the position control or process control is automatically processed. In the MANUAL
mode the valve can be opened or closed manually.

• Configuration level:
Specify the basic functions on initial commissioning and select further additional functions within the configuration level.

Process mode Configuration mode

5s
Basic func-
MANUAL AUTO- Additional
tions
MATIC menu
End

Fig. 6.2: Changing between the operating levels

TopControl Continuous 117

6.3 Commissioning as a position controller

➔ Follow the pneumatic and electrical connection instructions before commissioning (chapter 5).

6.3.1 Basic configuration

➔ Select the following basic configuration for the initial commissioning :

• Enter the displacement range of the pneumatic actuator.

• Enter the unit of the selected input signal (4..20 mA, 0..20 mA, 0..10 V or 0..5 V).

• Start the self-calibration of the TopControl Continuous to the selected operating conditions(Autotune).

6.3.2 Operating mode for basic configuration

Assignment of the keys:

MANUAL/AUTOMATIC key Changing between main- and submenu

e. g. ACT FUNC - FUNCSNGL

Arrow keys Changing between same level functions

e. g. ACTFUNC - INPUT

118 Operating instructions no. 800607

 Main menu for configuration during servicing:

AUTOMATIC
Mode 5s

MANUAL
Mode

Omit during first commissioning

5s

Fig. 6.3: Setting within the main menu

TopControl Continuous 119

 Description of the overview (Fig. 6.3):

After switching the power on, the TopControl Continuous is in the process operation level in the AUTOMATIC mode. To enter the
basic configuration, within the configuration level, press the MANUAL/AUTOMATIC key for a duration of 5 seconds. The submenu
ACTFUNC will then be displayed as the first step of the main menu.

To enter the sub-menu ACTFUNC quickly press the MANUAL/AUTOMATIC key. One of the functions of the sub-menu will be
displayed. To move between the different functions, press the arrow keys, additionally enter any desired settings. Press the MA-
NUAL/AUTOMATIC key to validate the wished settings after selection.

NOTE The selected function is displayed on 3 or 4 digits right of the 8-characters LCD. These digits will blink on
the display.

Actfunc
Functions of the actuator

➔ Enter in this sub-menu the configuration of the pneumatical actuator used with the TopControl. See the instrument label for
function valve description.

- single acting

- double acting

Input
Selected input signal

➔ In this sub-menu enter the unit used for the setpoint value.

- Current 4..20 mA

- Current 0..20 mA

- Voltage 0..10 V

- Voltage 0..5 V

Addfunct
Configuration of the additional functions (see Fig. 6.4)

➔ Omit this function during the initial operation.

120 Operating instructions no. 800607

 X.tune
Autotuning of the TopControl Continuous

➔ With the X.TUNE sub-menu, you start a program that performs an automatic parametring of the TopControl Continuous.

The following parameters are automatically calculated:

• Matching the sensor signal to the (physical) stroke of the control valve

• Determining the parameters of PWM signals controlling the internal solenoid valves

• Optimum adjustment of the control parameters of the position controller (target function: quickest possible movement to
set the position without hunting)

➔ To start the autotune function, call the X.TUNE option within the main menu, then leave it by pressing the MANUAL-AUTOMATIC
key for 5 seconds.

Start of the automatic adjustment of the TopControl Continuous to the operating conditions

Display Description

TUNE 5 Countdown from 5 to 0, before starting the

autotune 5s
TUNE 4
:
TUNE 0

¦ X.TUNE 1 Display the already passed steps of the

autotune procedure
¦ X.TUNE 2 (The advancement is figured on a varying
barchart (displayed on the right)
¦ X.TUNE 3 hand side of the LCD)
¦ X.TUNE 4
:

X.TUNE.END Blinking display => End of the autotune

function

X.ERR X.X Display in error occurence

(right display: error number; see chapter 7)

Fig. 6.4: Display during launching and performing the autotune

Advice: The basic configuration of the TopControl is pre-set by the factory. On commissioning, however, execution of
”Autotune” is absolutely necessary. The TopControl then determines autonomously the optimum settings for
the current operating conditions.

ATTENTION!
Avoid incorrect adaptation of the controller by executing an Autotune in each case at the supply pressure
available in later operation (= pneumatic auxiliary energy).
If substantial interfering forces are to be expected from the flow through the valve (e.g. from large
pressure fluctuations), Autotune should be executed without medium pressure.

END
Quit the main menu and display the version of the software

➔ In order to quit the main menu, select the submenu END with the arrow key, then validate. On the right hand side of the screen,
the software version is displayed (End xx).Press the MANUAL/AUTOMATIC key for 3-5 seconds, and the message EEPROM
appears on the display during the storage of the changes. The instrument is then in the previous mode (MANUAL-
AUTOMATIC), before the main menu is entered.

TopControl Continuous 121

6.4 Configuration of the additional functions

NOTE The operating concept of the TopControl Continuous is based on a separate basic and additional functions.
Only the basic functions of the unit are activated on delivery. This enables the basic settings such as specific
units to be set during the initial setting up of the unit (Chapter 4). These are sufficient for the normal
operations.

For more demanding tasks of position and process control, additional functions can be selected and
configurated.

6.4.1 Keys in the configuration menu

Key description within the Menu within a selected sub-menu

Arrow up key Increase of the numeric value

Arrow down key Decrease of the numeric value

Key description within the Menu within the menu ADDFUNCT

Validation of the selected Validation of the selected sub-menu of the additional

sub-menu functions for use within the main menu. The sub-menu
is marked with a star (*) within the main-Menu and can
there be selected and modified.

Validation of the selected value Selection of the selected submenu (marked with a star) in
order to suppress it from the main menu.

6.4.2 Configuration menu

Process mode Configuration mode

5s
Basic func-
MANUAL AUTO- Additional
tions
MATIC menu
END

Fig. 6.5: Switch between process mode and configuration mode

➔ 5s Within process mode, press the MANUAL/AUTOMATIC key and hold down for 5 sec to activate the
configuration mode.

The configuration menu is constituted of the main menu and the additional menu. The main menu will contain the functions as
specified during the initial commissioning (Chapter 4). The additional menu contains complementary functions and is available
through the ADDFUNCT menu within the main menu. If necessary, you may complete the main menu with functions from the
additional sub-menu, which you can then specify.

122 Operating instructions no. 800607

 Selection of additional functions within the main menu

➔ Select the sub menu ADDFUNCT within the main menu.

➔ By pressing the MANUAL/AUTOMATIC key, enter within the additional sub-menu.

➔ Select the required function with the arrow-keys.

➔ By pressing the MANUAL/AUTOMATIC key, validate the additional function within the main menu. The function is marked with
a star (*).

➔ All functions are activated within the main menu after validation through ENDFUNCT.

➔ Enter the parameters of the additional functions within the main menu.

Withdrawal of additional functions from the main menu

➔ Select the sub menu ADDFUNCT within the main menu.

➔ By pressing the MANUAL/AUTOMATIC key, enter within the additional sub-menu.

➔ Select a function marked with a star (*) by mean of the arrow-keys.

➔ By pressing the MANUAL/AUTOMATIC key, withdraw the additional function from the main menu (the marking star (*) is
removed).

➔ The function is deactivated from the main menu after validation through ENDFUNCT.

Entry of numeric values

Enter the numeric values in the previous functions by pressing one or several times the arrow up key (to increase the value) or
the arrow down key (to decrease the value). If the value is displayed with 4 digits, only the blinking one can be changed with the
arrow key. Pressing the MANUAL/AUTOMATIC key moves to the next position.

Main menu
Validation of the Additional menu
ACTFUNC selected function
Selection of I N P U T
the ADDFUNCT *CHARACT
ADDFUNCT X . T U N E C U T O F F
sub-menu DIRECTN
E N D
S P LT R N G
X . L I M I T
Return to the exten- *X.CONTRL
ded main menu * P. C O N T R L
ENDFUNCT

Validation of the selected additional

ACTFUNC functions and adding to the main
I N P U T menu
Extended
CHARACT
main menu X.CONTRL
P. C O N T R L
ADDFUNCT
X . T U N E
P. Q ' L I N
E N D

Fig. 6.6: Principle of the selection of an additional function to the main menu

TopControl Continuous 123

6.4.3 Additional functions

Selection of the transmission characteristic

curve between the input signal and stroke
(correction characteristic curve)

Close tight function

Relationship between the input signal and the

setpoint

Relationship between the indicated position value

and the air supply state (Connection 21)

Split range: min. and max. value in % of the set

value range of the TopControl Continuous

Stroke limitation to a given min. and max. value

Speed limitation to open or close the valve

Top Control Continuous configuration

Process controller configuration

Protection code for configurations

Operation of binary input

Output configuration

User calibration

Back to factory setting

124 Operating instructions no. 800607

 Charact
Selection of the transmission characteristic curve between the input signal and the stroke (correction characteristic
curve)
User specific characteristic curve (Characteristic)
Factory setting: CHA LIN

With this function you select a transmission characteristic curve in relation to the position set value (position setpoint) and to the
valve stroke to correct the flow rate respectively the operating characteristic curve.

linear characteristic curve

equal percentage characteristic curve,

1 : 25
equal percentage characteristic curve,
1 : 33
equal percentage characteristic curve,
1 : 50
inverse equal percentage,
25 : 1
inverse equal percentage,
33 : 1
inverse equal percentage,
50 : 1
user specific freely programmable
characteristic curve based on
temporary restart points

The flow characteristic kv = f(s) characterises the flow of a

valve and is expressed by the kv value relative to the stroke Standard
s of the valve spindle. It is determined by the shape of the valve stroke [%]
valve body. There are normally two types of flow
characteristic curves: linear and equal percentage.

In the case of linear characteristic curves equal changes

in stroke ds are assigned to equal kv value changes dk v

(dkv = nlin ds).

In the case of an equal percentage characteristic curve,

a change in stroke ds corresponds to an equal
percentage change in the kv value
Standard
position setpoint [%]
(dkv/kv = nequalperc ds).

Fig. 6.7: Corrective characteristic curves

The operating curve Q = f(s) represents the relationship between the rate of flow Q which flows through a valve fitted in the system
and the stroke s. This curve is also affected by the properties of the pipelines, pumps and consumers. It therefore has a form,
which deviates from the flow characteristic curve.

Specific requirements are usually laid down for the operating characteristic curve (e.g. linearity) in the case of correcting tasks for
closed loop control systems. Therefore it is sometimes necessary for this reason to correct the pattern of the operating curve in a
suitable manner. A transmission element, which implements various characteristic curves that can be used to correct the
operating curve, is provided in the TopControl Continuous for this purpose.

The equipercentile curves 1:25, 1:33, 1:50, 25:1, 33:1 and 50:1 and a linear characteristic may be set. Furthermore, it is possible
to programme any characteristic via reference points or have it calibrated automatically.

TopControl Continuous 125

 Input of the freely-programmable characteristic curve

The characteristic curve is defined by means of 21 restart points distributed uniformly over the set positioning range of 0 ... 100%.
These are spaced at 5%. A freely selectable stroke (range 0 ... 100%) can be assigned to each restart (Fig. 6.8). The difference
between the values of the stroke of two adjacent restart points shall not exceed 20%.

To input the characteristic curve points (function values), the CHA FREE menu item is first set.
After operation of the MANUAL/ AUTOMATIC key the first restart point is input with the display 0 (%). After this the next function
value is 0 (%).

A function value from 0 to 100% can be set using the arrow keys. After confirmation using the MANUAL/AUTOMATIC key the next
restart point is shown on the display etc. If finally the MANUAL/AUTOMATIC key is pressed to confirm the function value for the
last restart point (100%), the program switches back to the CHARACT menu item.

Valve
stroke
[%]

Input signal
[%]

Entry of the position:

Valve stroke [%] return

(input with the arrow keys) to
CHARACT
Position setpoint [%]
(restart points)

Fig. 6.8: Example of the free programming of a correction curve

NOTE A table for noting the reference points entered is to be found in the Annex

126 Operating instructions no. 800607

Note: .
 Cutoff
Close tight function

Factory setting: CUT = 1 %; CUT = 99%

The closed tight function ensures that the valve is tightly closed outside the control range. Specification of a value (%) from which
the actuator air is completely exhausted or supplied with air. With the fast pressurizing/venting version, two valves are driven
in each case in order to completely vent and pressurize more rapidly. The opening or resumption of the control operation
takes place with a hysteresis of 1% (refer to Fig. 6.9).

Exhaust aired (0 % inactive)

Range: 0.0 ... 10.0 % for complete exhausting

Filled with air (100 % inactive)

90.0 ... 100 % for complete air supply

Programmable from 75,0 to 100,0 %

Plug travel
[%]

Setpoint [%]

Programmable from 0,0 to 25,0 %

Fig. 6.9: Closed tight function

Dir.cmd
Direction of command of the setpoint of the actuator

Factory setting: DIR.CRISE

With this additional function, the direction of action according to setpoint of the actuator and the input signal (Fig. 6.10).

Rise direction
(i.e. 4 mA bzw. 0 V → 0%
20 mA bzw. 5/10 V → 100%)

Fall direction
(i.e. 4 mA bzw. 0 V → 100%
20 mA bzw. 5/10 V → 0%)

TopControl Continuous 127

 Setpoint

RISE

FALL

Input signal

Fig. 6.10: Sense of action between input signal and setpoint

Dir.act
Relationship or direction of the actuator

Factory setting: DIR.ARISE

This function determines the direction of action between the air supply state and the actual value indication of the actuator
(Fig. 6.11).

Direct command
(exhausted → 0% supplied → 100%)

Inverse command
(exhausted → 100% supplied → 0%)

Set position
RISE

FALL

exhausted supplied Air supply

state
Fig.6.11: Relationship between air delivery state
of the actuator and the actual value

128 Operating instructions no. 800607

 SPLtrng
Splitrange; minimal and maximum values of the input signal (in %) generating the complete displacement of the valve all over the
plug range.

Factory setting: SR = 0 (%); SR = 100 (%)

This additional function enables the set value range of a TopControl Continuous to be restricted by stipulating a minimum and
maximum value. This makes it possible to divide the used unit signal range (4..20 mA, 0..20 mA, 0..10 V oder 0..5 V) over several
TopControl Continuous (without or with an overlap). In this way, several valves can be partially used either simultaneously or in
sequence as a final controlling element (Fig. 6.12).

Entry of the minimal value of the input signal in % (0... 75 (%)

of the measuring range)

Entry of the maximum value of the input signal in %

(25... 100 (%) of the measuring range)

Plug travel [%]

Setpoint
[mA]
Fig. 6.12: Splitting a unit signal range into Setpoint range Setpoint range
two set value ranges Top Control Top Control
Continuous 1 Continuous 2

TopControl Continuous 129

 X.limit
Mechanical stroke limitation

Factory setting: LIM = 0%, LIM = 100%

This additional function enables the (physical) stroke to be limited to a given MIN and MAX percentage value (Fig. 6.13).
There, the stroke range of the limited stroke is set to equal 100%.

If during servicing the selected plug travel is overpassed, then the display of POS value may be greater than 100 % or lower
than 0%.

Entry of the lower value of the stroke range in %

0..50% of the total stroke

Entry of the upper value of the stroke range in %

50..100% of the total stroke

The minimum distance between LIM and LIM is 50%

Limited plug Physical plug

travel [%] travel [%]

Unlimited plug
travel
Control range in automatic mode
Control range in manual mode

Limited plug
travel

Setpoint [mA]

Fig. 6.13: Stroke limitation

X.time
Setting speed limitation

Factory setting: No limitation

On execution of the function X.TUNE, the minimum opening and closing times for the entire stroke are entered in T.OPN and
T.CLS automatically. In this way, operation at maximum speed is selected.

If the control speed is to be limited, values for T.OPN and T.CLS may be entered that lie between the minimum values
determined by X.TUNE and 60 s.

Opening speed

Entry in s

Closing speed

130 Operating instructions no. 800607

 Valve stroke
[%]

Set-point
value

Actual
value

t
T.OPN

Fig. 6.14: Effect of limiting the opening speed for a jump in the set-point value

X.contrl
Parameters setting for the TopControl Continuous

Deadband of the TopControl Continuous

Enter the deadband in % ( 0 = automatic) Factory setting: 1 %

This function ensures that the TopControl Continuous acts only then a selected control difference is measured (Fig. 6.14).
This function protects the servovalve and pneumatic actuator by controlling the start-up frequency.
The setting is optimized automatically with X.TUNE.

Parameter of the position controller

Proportional factor for the TopControl Continuous (to close the valve)

Proportional factor for the TopControl Continuous (to open the valve)

End of the parametering of the TopControl Continuous. Return to X.CONTRL

TopControl Continuous 131

 Xd1'

Control
Position setpoint difference to the controller

Xd1 Xd1'
Xd1

Actual DBND
position

Fig. 6.15: Deadband by position control

P.control
Parameters setting of the process controller

Dead band of the controller

Parameters of the PID controller

Mode of setpoint entry

Filtering of the process actual value input

Scale of the controller

Storage of the new parameters

End of the parametering setting of the controller

P.co - dbnd
Deadband of the process controller Factory setting: 1% (relative to the range of the selected
process set-point input

This function ensures that the postioner acts only then a selected control difference is measured (Fig. 6.15). This function
protects the servovalve and pneumatic actuator by controlling the start-up frequency.

Entry of the deadband in %

132 Operating instructions no. 800607

 Entry of the dead band in % relative to the range of the selected process set-point input

Input type used for Range Spread (as reference Example:

PV for the dead band) 1% dead band corresponds to

4..20 mA 4 .. 20 mA 16 mA 0,16 mA

Frequency 0 .. 1000Hz 1000 Hz 10 Hz

Pt100 -20 .. +220°C 240°C 2,4°C

Xd2'

Control
Position setpoint difference to the controller

Xd2 Xd2'
Xd2

Actual DBND
position

Fig. 6.16: Deadband by process control

P.co - para
Controller PID parameters

Proportional correction value

0...99.99 (factory setting 1.00)

Reset time
0.5...999.9 (factory setting 999.9)

Rate action time

0.5...999.9 (factory setting 0)

Operating point of process controller

0.0...100 % (factory setting 0 %)

See Appendix

NOTE A table for noting the reference points entered is to be found in the Annex

TopControl Continuous 133

 P.co - setp
Type of setpoint (internal/external)

Internal setpoint by keys on the TopControl

External setpoint by analogue input

P.co - inp
Analogue input type
Enter the analogue input signal type according to the transmitter signal.

Analogue input 4...20 mA

(Flow; Pressure; Level; Analytical)

Analogue input Frequency (Flow)

Analogue input Pt100

(Temperature)

P.co - filt
Filtering of the process actual values. Valid for all process actual value types.

Range: 0..9 Works setting: 0

FILT xx
Setting in 10 steps: 0..9

Setting in 10 steps

Setting Limiting frequency [Hz] Effect

0 10 minimum filter effect

1 5

2 3

3 2

4 1

5 0,7

6 0,5

7 0,3

8 0,2

9 0,1 maximum filter effect

134 Operating instructions no. 800607

 P.CO SCAL
A) Scale limit for process control by selection of "4 ..20 mA" (P.CO inp 4-20A)
(example see below)

Position of the decimal point for the process setpoint and

actual value
(Selectable value: 0..3)

Lower range value for process actual value

(process value);
value assigned to 4 mA.

Higher range value for process actual value

(process value);
value assigned to 20 mA.

Lower range value for process setpoint

(setpoint); assigned to the highest current/voltage value
of the external setpoint signal.
This setting is only activated if
P.CO SETP / SETP EXT is selected.

Higher range value for process setpoint

(setpoint); assigned to the lowest current/voltage value
of the external setpoint signal.
This setting is only activated if P.CO SETP / SETP EXT is
selected.

Scale limit selection example for the 4..20 mA input (Fig. 6.16):

Actual process value of the transmitter: 4..20 mA match 0..10 l/min

Process setpoint of the SPS: 4..20 mA match 0..8 l/min

Example for scale value entries

Scale limit Process
[l/min] value Variant 1 Variant 2 Variant 3

PV 0 0 0
PV 1.0 10.0 100.0
Process SP 0 0 0
setpoint SP 0.8 8.0 80.0

Input signal
[mA] Fig 6.16: Example of scale limit for controller input

NOTE On entry of small scaling values, to increase the display accuracy, places after the decimal point are
automatically added, so that the maximum possible digit range is obtained between the lower and upper
scaling value in each case.
The amplification (KP) of the process controller relates to scale values set.

With P.CO SETP / SETP INT (desired value pre-set via the arrow key), no scaling of the desired value SP and
SP not possible. It can be entered directly in correspondence with the scaled process variable (PV , PV ).

TopControl Continuous 135

 B) Scale limit for process control by selection of frequency input (P.CO inp Freq)

NOTE The valve is closed as this menu is activated. Then, the Teach-In is performed with a defined output
conditions.

Unit l/s

Unit l/m

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

136 Operating instructions no. 800607

 Entry of the required flow unit

Position of the decimal point for the process setpoint and actual value (Selectable value: 0..3).

Lower range value for process setpoint ;

assigned to the lower current/voltage value of the external setpoint signal.
This setting is only activated if P.CO SETP / SETP EXT is selected.

Higher range value for process setpoint;

assigned to the higher current/voltage value of the external setpoint signal.
This setting is only activated if P.CO SETP / SETP EXT is selected.

Manual entry of the K-factor of the flow sensor (refer to the data sheet of the flow sensor)

Position of the decimal point of the K-factor (Selectable value: 0..2)

K-factor (range: 0..9999)

Teach-In-Function:
Calculation of the K-Factor, by measuring a known fluid volume .

Starting the measurement.

- Run the pump or open the valve.

The tank is full, shut the pump or close the valve.
- Open and close the valve with the arrow keys.
The valve must not be tightly open.

End of the measurement.

Position of the decimal point of the measured volume

(Selectable value: 0..3).

Enter the measured volume (Selectable value: 0..9999).

Unit as previously selected UNITXXXX.

Display of the calculated K-Factor

TopControl Continuous 137

 C) Scale limit for process control with Pt100 (P.CO inp pt100)

Position of the decimal point for the process setpoint and

actual value (Selectable value: 0..3)

Lower range value for external process setpoint

Assigned to the lower current/voltage value of the
external setpoint signal (this setting is only activated if
P.CO SETP / SETP EXT is selected).

Higher range value for external process setpoint

Assigned to the higher current/voltage value of the
external setpoint signal (this setting is only
activated if P.CO SETP / SETP EXT is selected).

CODE
Code protection for the settings

Factory setting: Code 0000

Blocking of all actions that would change the operating

status of the device.
The contents of the display can be switched over.

Blocking of entry into the configuration level.

Entry of the 4-digit code

When code protection is active, the entry code is demanded every time a blocked operation is attempted:

Alteration of the flashing place/digit

Confirmation of the digit and switching to the next place

138 Operating instructions no. 800607

 BIN-IN
Configuration of the binary input

Selection of the function of

the binary input

Searching of a security
position

Binary input not activated

Enter the security position

(0..100%) *

Type of binary input

normally closed
(0..5 V = 1; 10..30 V = 0)

normally open
(0..5 V = 0; 10..30 V = 1)

End of the binary input

function

* If the safety position is 0 or 100%, the actuator is completely vented or pressurized, respectively, as soon as the
relevant signal is applied to the binary input.
With the fast pressurizing/venting version, two valves are driven in each case in order to completely vent and
pressurize more rapidly.

Output Option
Configuration of the output signals

Setting the analogue output

(see next page)

Setting the binary output

(see next page)

End of the configuration of the output signals

TopControl Continuous 139

 out ANL Unit of analogue position indication

analog output of the actual position of the valve actuator

analog output of the set position of the valve actuator

with process controller active: analog output of the set

value of the process (option)
with process controller active: analog output of the actual
value of the process (option)

Current 4..20 mA

Current 0..20 mA

Voltage 0..10 V

Voltage 0..5 V

out bin Configuration of the output signal

normally closed
allowed control
range*
normally open

normally closed

lower threshold
(output 1)
normally open

normally closed
higher threshold
(output 2)
normally open

OUT DEV Choice: Alarm output for high control deviation (output 1)
* the selected control deviation Dev xxx must not be lower than the deadband.

norm cls The output functions as normally closed output.

norm opn The output functions as normally open output.

OUT lim Choice: 2 binary position output signals

lower threshold (output 1)

higher threshold (output 2)

norm cls The output functions as normally closed output.

norm opn The output functions as normally open output.

140 Operating instructions no. 800607

 cal.user
Calibration of the actual value display, entries for position and process control setpoint, process value, and K-Factor of
the valve.

A) POSITION CONTROL ACTIVATED

Description see next page

only activated in case of analogue position indication

end of the calibration

NOTE The signal values within parenthesis are only available as a display and cannot be modified. The type of
signal as previously selected in the configuration menu is displayed:
CAL Inp: Display of the selection within the INPUT menu
CAL OUT: Display of the selection within the outPUT menu

TopControl Continuous 141

 CAl.pos Calibration of the position indication (0 - 100 %)
Entry of the minimal position: set the minimal position of valve with the arrow key, then validate by
pressing the MANUAL/AUTOMATIC key

Entry of the maximal position:

set the valve to the maximal position with the arrow key, then validate by pressing the MANUAL/
AUTOMATIC key

cal inp Calibration of the position setpoint (4..20 mA; 0..20 mA; 0..5 V; 0..10 V)
Entry of the minimal input signal (0 mA; 4 mA; 0 V):
set the minimal input signal with the arrow key, then validate by pressing the MANUAL/AUTOMATIC
key

Entry of the maximal input signal (20 mA; 5 V; 10 V):

set the maximal input signal with the arrow key, then validate by pressing the MANUAL/AUTOMATIC
key

cal out Calibration of the analogue signl output (4..20 mA; 0..20 mA; 0..5 V; 0..10 V)

Adjustment of the minimal output signal (0 mA; 4 mA; 0 V):

Change the minimal output signal with the arrow key until the displayed value is correct, then validate by
pressing the MANUAL/AUTOMATIC key.

Adjustment of the maximal output signal (20 mA; 5 V; 10 V):

Change the maximal output signal with the arrow key until the displayed value is correct, then validate by
pressing the MANUAL/AUTOMATIC key.

Cal out is only activated in case of analogue position indication!

Cal fact Return to the factory setting within the Cal.user function:
Press the MANUAL/AUTOMATIC key until the countdown elapsed.

142 Operating instructions no. 800607

 B) PROCESS CONTROL ACTIVATED

Description see next page

only activated in
case of analogue
position indication

end of the calibration

NOTE The signal units within parenthesis are only available as a display and cannot be modified. The type of
signal as previously selected in the configuration menu is displayed:
CAL PV: Display of the selection within the P.co.inp menu
CAL Sp: Display of the selection within the P.co.setp menu
CAL OUT: Display of the selection within the outPUT menu

TopControl Continuous 143

 CAl pos Calibration of the position indication
Entry of the minimal position:
Set the minimal position of valve with the arrow key, then validate by pressing the MANUAL/
AUTOMATIC key

Entry of the maximal position:

Set the valve to the maximal position with the arrow key, then validate by pressing the MANUAL/
AUTOMATIC key

cal sp Calibration of the position setpoint; the type of setpoint (4..20 mA; 0..20 mA; 0..5 V; 0..10 V) was
selected in the INput menu

Set the minimal setpoint (0 mA; 4 mA; 0 V) with the arrow key, then validate the value by pressing the
MANUAL/AUTOMATIC key

Set the maximal setpoint (20 mA; 5 V; 10 V) with the arrow key, then validate the value by pressing the
MANUAL/AUTOMATIC key

cal pv Calibration of the actual process value ; the type of the actual process value (4..20 mA; Pt 100) was
selected in the PCO-inp menu

if 4..20 mA selected:
Set the minimal input then validate by pressing the MANUAL/AUTOMATIC key

Set the maximal input signal then validate by pressing the MANUAL/AUTOMATIC key

if Pt-100 selected:
Correct the displayed value with the arrow key until the display on the TopControl is in accordance with
the reference measuring instrument, then validate by pressing the MANUAL/AUTOMATIC key.

cal out Calibration of the analogue signl output (4..20 mA; 0..20 mA; 0..5 V; 0..10 V)

Adjustment of the minimal output signal (0 mA; 4 mA; 0 V):

Change the minimal output signal with the arrow key until the displayed value is correct, then validate
by pressing the MANUAL/AUTOMATIC key .

Adjustment of the maximal output signal (20 mA; 5 V; 10 V):

Change the maximal output signal with the arrow key until the displayed value is correct, then validate
by pressing the MANUAL/AUTOMATIC key.

Cal out is only activated in case of analogue position indication!

Cal fact Return to the factory setting within the Cal.user function:
Press the MANUAL/AUTOMATIC key until the countdown elapsed.

setfact
Return to the factory setting

This function allows the user to return to the initial factory setting. All EEPROM parameters are reset to default value. Finally a
complete hardware reset of the instrument is performed.

Press the MANUAL/AUTOMATIC key during

3s
ca. 3 seconds, until the countdown elapsed.

144 Operating instructions no. 800607

6.5 Setting a process control function

In order to use the TopControl Continuous as a process controller, apply the following requirements:

➔ Perform first the self-calibration procedure for the position controller (X.TUNE - see 6.3.2).

➔ Select the P.CONTRL additional function within the configuration mode in the main menu (see 6.4).

The function P.CONTRL will also be activated into the main menu.

➔ Enter the basic configuration of the process controller within the P.CONTRL function (see 6.4).

If the process control acts on a flow process control, it is possible to use the automatic linear characteristic curve of
the process:

➔ Release the function P.Q’LIN (see 6.5.1).

ATTENTION!
Perform the functions in the following order, in any case! X.TUNE
P.Q’LIN

6.5.1 Starting the function to obtain linear characteristic curve

P.Q’LIN
This function is only useful for a flow process control

➔ Start the function to obtain the automatic linear characteristic curve by selecting the function P.Q’LIN within the main menu
and pressing the MANUAL/AUTOMATIC key during 5 seconds.

NOTE It is only possible to activate the function P.Q'LIN within the main menu if the functions P.CONTRL / P.COINP /
INPFREQ or P.CONTRL / P.COINP / INP4'20mA has been selected.

By activation of the function P.CONTRL the function P.Q’LIN is automatically copied within the main menu. Start the function to run
the program to obtain the automatic correction curve.

The program increases the valve stroke in 20 steps from 0 to 100 % and measures the associated process variable. The couple
of points of the correction characteristic curve are used within the sub-menu CHARACT/CHAFREE as a free programmable
characteristic curve, and can be checked within this sub-menu.

If the function CHARACT was not previously, transferred within the main menu by the sub-menu ADDFUNC this will be automatically
performed by the call to the P.Q'LIN function, and the function CHARACT/CHAFREE will be simultaneously activated.

Display Description

P.Q’LIN 5 Countdown from 5 to 0 before starting

P.Q’LIN 4 the function
:
P.Q’LIN 0

¦ P.Q’LIN 0 Display the already passed steps of the function performed

¦ P.Q’LIN 1 (The advancement is figured on a varying bar chart
¦ P.Q’LIN 2 displayed on the right side of the LCD)
¦ P.Q’LIN 3
:

P.Q’LIN.END (flashing) End of the function

Q.ERR X.X Display in error occurrence

(right display: error number; see chapter 7)

Fig. 6.17 Display during launching and performing the linearisation function

TopControl Continuous 145

6.6 Process operation level

The process operating level is automatically set each time the unit is switched on. From configuration level you can change
over to the process operation level by using the MANUAL/AUTOMATIC key and after validation of the instruction END of the
menu.

The process operating level allows viewing of normal control functions (AUTOMATIC mode) and to open and close the valve
manually (MANUAL mode).

Change of operating levels:

To change over between MANUAL and AUTOMATIC operating mode press the
MANUAL/AUTOMATIC key.

From MANUAL or AUTOMATIC mode you can change over to the configuration level by pressing the
5s MANUAL/AUTOMATIC key for 5 seconds.
Returning to the process operation level, the unit operates in the last selected level before changing.

Operating mode Yellow LED in Display

MANUAL/AUTOMATIC key

AUTOMATIC flashing a quotation mark is continuously

flashing from left to right.

MANUAL off -

6.6.1 AUTOMATIC operating mode

In AUTOMATIC operating mode the system functions in the process control configuration.

Key functions in AUTOMATIC operating mode:

Display switching
or

Change of the process setpoint

or >3s If the additional function P.CONTRL / P.CO SETP / SETP INT is configured and SP selected

146 Operating instructions no. 800607

 Display indications in AUTOMATIC operating mode:

A) Process controller not active

The following information from the TopControl Continuous is possible:

• Actual position of the valve actuator : POS__xxx (0..100%)

• Set position of the actuator after scaling

i.e. split range function or characteristic curves modification: CMD__xxx (0..100%)

• Input signal for set position: INP__xxx (0..5/10 V or 0/4 .. 20 mA)

• Internal temperature of the TopControl Continuous: TEMP_xx.x (in °C)

By pressing the arrow keys you activate the changing over between the 4 display possibilities (Fig. 6.19).

AUTOMATIC Configuration
operating mode
Point of Menu

END

(> 5 s)
POS__xxx
or
CMD__xxx No activity
Chance over
of the
INP__xxx of the
Leave the key operator
display
TEMP_xx.x

MANUAL
operating mode

Fig. 6.19: Display, operation structure and operating instructions in AUTOMATIC mode with inactive process controller

NOTE When the menu item BIN IN / BIN FUNC / FUNC SPOS is active and the binary input is switched, the
message SAFE xxx appears in the display.
The value XXX indicates the previously selected safety position in %.

TopControl Continuous 147

 B) Active process controller

The following points are shown:

• Actual process value: PV___(-999..9999)

• Process set point: SP___(-999..9999)

• Actual position of the actuator: POS__xxx (0..100%)

• Set position of the actuator after scaling

i.e. split range function or characteristic curves modification: CMD__xxx (0..100%)

• Internal temperature of the TopControl Continuous: TEMP_xx.x (in °C)

By pressing the arrow keys you activate the changing over between the 6 display possibilities (Fig. 6.120).

AUTOMATIC Configuration
operating mode
Point of menu

END

PV___ (> 5 s)

SP___ or or
N o
SP S e t t i n g
Change over
POS__xxx a c t i v i - o f
of the t aktive
y
Leave the key Leave the key p r o c e s s
display
CMD__xxx

TEMP_xx.x

Manual
operating mode

Fig. 6.20: Display, operation structure and operating instructions in AUTOMATIC mode with active process controller

NOTE When the menu item BIN IN / BIN FUNC / FUNC SPOS is active and the binary input is switched, the
message SAFE xxx appears in the display.
The value XXX indicates the previously selected safety position in %.

148 Operating instructions no. 800607

 Manual modification of the process set-point:

If programming the additional functions P.CONTRL / P.CO SETP / SETP INT

or >3s is required, it is possible to activate the process set point mode by using one of the
arrow keys. Press the key for more than 3 sec. (Fig. 6.18, 6.19). After the first digit of
the process set point will blink.

Now select the first digit of the process set point. or

Validate the value with the MANUAL/AUTOMATIC key.

Use the same procedure for the next digits. After validating of the 4 th digit, the program automatically returns to the menu.

6.6.2 MANUAL operating mode (yellow LED off)

In the MANUAL operating mode the valve can be opened or closed manually.

Key functions in the MANUAL operating mode:

Pressing the ”up arrow” key:

Opens the actuator

Pressing the ”down arrow” key:

Closes the actuator

Continuously pressing the ”up arrow” and ”down arrow” keys simultaneous:
and Produces a quick opening action

Continuously pressing the ”down arrow” and ”up arrow” keys simultaneous:
and Produces a quick closing action

Display indications in MANUAL operating mode:

1. Process controller not active

• The last indication of the AUTOMATIC operation mode is displayed.

Selecting POS__xxx provides an option to check the actual value of the actuator.

2. Process controller active

• The last indication of the AUTOMATIC operation mode is displayed.

Selecting PV__xxx provides an option to check the actual value of the actuator.

• To display the actual value of the actuator during the MANUAL operation mode,
previously selected in the AUTOMATIC mode display POS__xxx.

Normal / Quick manual operating of the valve:

By continuously pressing the ”up arrow” key in the MANUAL operating mode, the valve is continuously opened.
To stop the function release the key and the valve will remain in the open position. By pressing the ”down arrow” key the valve will
be closed proportionally.

An additional pressing of the second arrow key generates a quick action of the valve (closing or opening) depending on the first
selected arrow (Fig. 6.21).

TopControl Continuous 149

 AUTOMATIC
mode

MANUAL
mode

Valve No activity Valve

closed - of the open -
Leave the key Leave the key
normal speed operator normal speed

Leave the key (> 5 s) Leave the key

Point of menu

Valve Valve
closed - END open -
high speed high speed
Configuration

Fig. 6.21: Operation structure and operating instructions in MANUAL mode

150 Operating instructions no. 800607

7 FAILURES AND REPORT ERRORS

The TopControl Continuous is maintenance free if used according to the recommendations of this manual.

7.1 Report errors on LCD display

• Faults during initial activation:

Message Possible cause Remedy

INT.ERROR Internal fault Not possible, unit defective

• Report errors during AUTOTUNE function:

Message Possible cause Remedy

X.ERR 1 Pressure supply not Connect the compressed air supply

connected

X.ERR 2 Air pressure failure during Control the compressed air supply
Autotune

X.ERR 3 Air supply of the actuator/ Not possible, unit defective

TopControl not secure

X.ERR 4 Exhaust air of the positio- Not possible, unit defective

ner not secure

• Error messages during execution of the P.Q’LIN function:

Display Causes of error Remedy

Q.ERR 1 No supply pressure connected Connect supply pressure

No change in process variable Check process, if necessary switch on pump or

open the shut-off valve

Q.ERR 2 Current reference point of valve

stroke was not reached because

• supply pressure failure occurred • Check supply pressure

during P.Q’LIN

• no AUTOTUNE was executed • Execute AUTOTUNE

7.2 Miscellaneous failures

Problem Possible cause Remedy

POS = 0 (by CMD > 0%) Close tight function (CUTOFF) Disactivate the close tight function
resp. is involuntary active (see 8.7.4)
POS = 100%, (by CMD < 100%)

TopControl Continuous 151

152 Operating instructions no. 800607
APPENDIX A

Selection criteria for continuous valves

For optional control behaviour and the reaching of the desired maximum flowrate the following criteria must be observed:

• The correct selection of the kV value, which is in fact defined by the valve size;

• The correct adjustment of the valve size to the pressure conditions, taking into account the pressure differences of the
installation.

Sizing guidelines can be given based upon the kV value. The kV value relative to the normal conditions for pressure, temperature
and fluid.

The kv value is the flowrate in m³/h though a piping port under a pressure difference of ∆p = 1 bar and T = 20°C.

For continuous valves the kVS value is used in addition. It corresponds to the kV value of a continuous valve, which is fully open.

In relation with the given data, we distinguish the two following cases for the sizing of the valves:

a) The pressures p1 and p2 must be known before and after the valve before the desired maximum flowrate Qmax can be
calculated:

The needed kVS value is calculated according to:

(1)
∆p0 ρ
kVS = Qmax ⋅ ⋅
∆p ρ0
Where:
kVS: maximal flowrate of fully opened continuous valve [m³/h]
Qmax: maximal volumetric flowrate [m³/h]
∆p0: = 1 bar; pressure drops of the valve according to the kV value defined
ρ0 : = 1000 kg/m³; density of water (according to the kV value definition)
∆p: pressure drop of the valve [bar]
ρ: density of fluid [kg/m³]

b) The pressures p1 and p2 at the inlet and outlet of the complete installation for the desired maximum flowrate Qmax can be
calculated:

1.Step: Calculation of the kVges value for the complete installation according to rule (1).

2. Step: Determination of the flowrate through the installation without a continuous valve (possible by by-passing the pipe
where the valve is installed).

3. Step: Calculation of the kVa value of the installation without the continuous valve according to rule (1).

4. Step: Calculation of the needed k VS value of the continuous valve according to rule (2):

1
kVS =
(2)
1 1
2
− 2
kVges kVa

Important rule:

The kVS value of the valve should reach at least the value calculated by the formula (1) or (2) depending on the application. It
should also not greatly exceed this value.
The often used rule for on/off valves ‘a little bit higher cannot be wrong’ can strongly influence the control behaviour of continuous
valves!

TopControl Continuous 153

 A practical rule for the determination of the kVS value for the upper limits in respect to continuous valves consists of using the so
called ‘valve authority Ψ :

(∆p)V 0 kVa 2
Ψ= =
(∆p) 0 kVa 2 + kVS 2
(3)

with
(∆p)V0: pressure drop with a fully open valve
(∆p)0: pressured drop over the complete installation

NOTE For valve authority Ψ < 0,3 the valve is oversized.

In this case, the flow resistance with a fully open valve is much lower than the other components of the
installation. This means that only in the lower opening range, the valve position is working according to the
characteristics. For that reason the characteristics are strongly deviated. This can be partially compensated
and the characteristics linearized within the limits by using an equal percentage characteristic between set
position and the plug travel.The valve authority Ψ should, even when using a corrected characteristic, be
> 0,1.

The control behaviour (standard choice, maximum adjustment time) is strongly dependent on the working
point when using a corrected characteristic.

154 Operating instructions no. 800607

Characteristics of PID controllers

A PID controller has a proportional, an integral and a differential component (P, I and D components).

P component:

Function: Y = Kp · Xd

Kp is the proportional action coefficient. It results from the ratio of the manipulating range ∆Y to the proportional range ∆Xd.

Manipulating range ∆Y

Proportional range ∆Xd

Characteristic Step response

Fig. 8.1: Characteristics and step response of the P component of a PID controller

Characteristics:

Theoretically, a pure P controller operates without delay, i. e. it is fast and therefore dinamically favorable. It has a lasting system
deviation, i. e. it does not balance out the effects of disturbances completely and is therefore relatively unfavorable from the static point
of view.

I component:

Function: Y= 1 ∫ Xd dt
Ti

Ti is the integration or manipulating time. This is the time that elapses before the manipulated variable has passed through the
complete manipulating range.
Manipulating range ∆Y

Control range ∆Xc

Manipulating time Ti

Characteristics Step response

Fig. 8.2: Characteristics and step response of the I component of a PID controller

TopControl Continuous 155

 Characteristics:

A pure I controller eliminates the effects of occuring disturbances completely. Therefore, it has a favorable static response. Owing
to its finite manipulating speed, it operates more slowly than the P controller and tends to oscillate. Therefore, it is relatively unfavorable
from the dynamic point of view.

D component:

Function: Y = Kd d Xd/dt

Kd is the derivative action coefficient.

The higher Kd is, the stronger the D influence is.

Step response Rise response

Fig. 8.3: Characteristics and step response of the D component of a PID controller

Characteristics:

A controller with a D component reacts to changes in the controlled variable and is accordingly capable of dissipating occurring
deviations faster.

Supperposition of P-, I- and D components:

Y = Kp Xd + 1 ∫ Xd dt + d Xd/dt
Ti

Where Kp · Ti = Tn and Kd/Kp = Tv, results with regard to functioning of the PID controller:

Y = Kp (Xd + 1 ∫ Xd dt + Tv dXd/dt)
Tn

Kp: Proportional action coefficient / gain

Tn: Reset time

(the time needed to achieve the same manipulated variable change by the I component as is produced as the
result of the P component)

Tv: Derivative action time

(the time to achieve a specific manipulated variable on the basis of the D component earlier than when using a
pure P controller)

156 Operating instructions no. 800607

 D component
I component
I Component
D component

P Component
P component

Reset time Tn Derivative action time

Tv
Step response of the PID controller Rise response of the PID controller

Fig. 8.4: Step response and rise response of the PID controller

Realised PID controller

D component with delay:

In the Top Control 8630, the D component is realised with a delay T.

dY dXd
Function: T + Y = Kd
dt dt

Superposition of P, I and DT components

Fig. 8.5: Superposition of P, I and DT components

TopControl Continuous 157

 Function of the real PID controller :

dY 1 dXd
T + Y = Kp (Xd + ∫ Xd dt + Tv )
dt Tn dt

Step response of the real PID controller:

Fig. 8.6: Step response of the real PID controller

158 Operating instructions no. 800607

Rules for adjusting PID controllers
The litterature on control systems specifies a series of adjustment rules with which a favorable adjustment of controller parameters
can be achieved experimentally. To avoid bad adjustments, the conditions under which the respective adjustment rules have been
elaborated must always be observed. In addition to the characteristics of the controlled system and of the controller itself, it is important
to know whether it is intented to balance out a disturbance change or a command variable change.

Adjustment rules according to Ziegler and Nichols (oscillation method)

When using this method, controller parameters are adjusted on the basis of the control loop's response at the stability limit. In doing
so, the controller parameters are adjusted so as to ensure that the control loop begins to oscillate. A conclusion as to a favorable
adjustment of the controller parameters is reached from critical characteristic values occurring in this case. It goes without saying that,
when using this method, it must be possible to bring the control loop to oscillation.

Method:

• Set the controller as a P controller (i.e. Tn = 999, Tv = 0), initially selecting a low Kp value

• Set the required setpoint.

• Increase Kp until the controlled variable oscillates continuously without attenuation (see following figure).

The proportional action coefficient set at the stability limit is referred as Kcrit. The resulting oscillation period is referred to as Tcrit.

Actual value

Tkrit

Time

Figure 8.7 : Progression of the control variable at the stability limit

On the basis of Kcrit and Tcrit, the controller parameters can then be calculated in accordance with the following table.

Parameter settings according to Ziegler und Nichols :

Controller Type Parameter settings

P controller Kp = 0,5 Kkrit - -

PI controller Kp = 0,45 Kkrit Tn = 0,85 Tkrit -

PID controller Kp = 0,6 Kkrit Tn = 0,5 Tkrit Tv = 0,12 Tkrit

The Ziegler and Nichols adjustment rules were determined for P systems with a time delay of the first order and a dead time. However,
they apply only to controllers with a disturbance response, but not to controllers with a command response.

Adjustment rules according to Chien, Hrones and Reswick (manipulated variable methode)

When using this method, the controller parameters are adjusted on the basis of the control system's transition response. A 100%
change in the manipulated variable is output. The time Tu and Tg are derived from the progression of the actual value of the control
variable (following figure).

TopControl Continuous 159

 Correcting
variable Y

∆Y
t
Actual value
Ks * ∆Y

Controlled
variable
∆X

t
Tu Tg

Figure 8.8: Progression of the controlled variable after a manipulated variable change ∆Y

Method:

• Set the controller to MANUAL mode

• Output a manipulated variable change and record the controlled variable with a recorder

• Switch off in good time if you encounter critical progressions (e. g. a risk of overheating).

NOTE Pay attention to the fact that, in thermally inert systems, the actual value of the controlled variable may
increase further switching off.

The following table lists the settings for the controller parameters depending on Tu, Tg and Ks for command and disturbance response
and for an aperiodic control operation as well as a control operation with 20% overshoot. They apply to systems with a P response,
with a dead time and with a delay of the 1st order.

Parameter settings according to Chien, Hrones and Reswick:

Parameter settings
Controller Aperiodic control operation Control operation
type (0 % overshoot) with 20 % overshoot

Command Disturbance Command Disturbance

P controller Tg Tg Tg Tg
Kp = 0,3 Kp = 0,3 Kp = 0,7 Kp = 0,7
Tu*Ks Tu*Ks Tu*Ks Tu*Ks

Tg Tg Tg Tg
Kp = 0,35 Kp = 0,6 Kp = 0,6 Kp = 0,7
Tu*Ks Tu*Ks Tu*Ks Tu*Ks
PI control-
Tn = 1,2 Tg Tn = 4 · Tu Tn = Tg Tn = 2,3 · Tu
ler

Tg Tg Tg Tg
Kp = 0,6 Kp = 0,95 Kp = 0,95 Kp = 1,2
Tu*Ks Tu*Ks Tu*Ks Tu*Ks
PID con-
Tn = Tg Tn = 2,4 · Tu Tn = 1,35 · Tg Tn = 2 · Tu
troller
Tv = 0,5 · Tu Tv = 0,42 · Tu Tv = 0,47 · Tu Tv = 0,42 · Tu

The proportionality factor Ks of the controlled member is given according to Figure 8.8 by:

∆X
Ks =
∆Y

160 Operating instructions no. 800607

APPENDIX B:
OPERATING STRUCTURE OF THE TOPCONTROL CONTINUOUS

TopControl Positioner 161

 PCO INP = 4'20A

Only in the case of external

set values
PCO INP = FREQ

Only in the case of external

set values

PCO INP = FREQ

Only in the case of external set values

162 Betriebsanleitung-Nr. 800607

 Position
controller
active

Process
controller
active

Process
controller
active

Analog
position
feedback

TopControl Continuous 163

164 Operating instructions no. 800607
APPENDIX C

TABLES FOR YOUR SETTINGS

Settings in the freely programmable characteristic

Ref. point Valve stroke [%]

(Set point of
position in %) Date: Date: Date: Date:

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

Parameters set in the process controller

Date: Date: Date: Date:

KP

TN

TV

X0

DBND

TopControl Continuous 165

NOTES

166 Betriebsanleitung-Nr. 800607

TopControl Continuous 167