Type

8750

Flow controller
Fluid-Mengen-Regler
Système de régulation de débits de fluide FMR type 8750

Short Instructions for Commissioning

Kurzanleitung zur Inbetriebnahme
Brève notice de l’utilisateur
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.

© 2003 - 2008 Bürkert Werke GmbH & Co. KG

Operating Instructions 0802/07_EU-ML_00804609

 INSTALLATION

Contents

Note on these short operating instructions 2

Symbols 3
Intended use 3
Safety notes 4
Transport, storage 4
Disposal 4
Description 5
Sequence of steps from assembly up to commissioning a system 6
Technical data 7
Dimensions 8
Intake sections to EN ISO 5167-1 8
Action diagram 8
Installation in a system 9
Connection of the control air 9
Electrical connections 9
Electrical interfaces 10
PIN designation and PIN allocation 10
Prefabricated cables as accessories 11
Kv-value table for various FMR versions 12
Process operating level and configuration level 13
Display and key functions 13
Key functions in the process operating level 13
Key functions in the configuration level 13
Factory settings and necessary user settings 13
Program sequence for commissioning (menu items and explanations) 14
Program function P.CO TUNE (PROCESSTUNE) 20
Prerequisites for starting P.CO TUNE (PROCESSTUNE) 20
Preparation for entry of a setpoint step for PROCESSTUNE 20
Explanations concerning starting value 21
Possible display of process values in the automatic mode 21
Entering the setpoint step and initiating PROCESSTUNE 21
Evaluation of control results after commissioning 22
Measures for improving the control behaviour 22
Program function P.CO LEAK (leak detection) 22
Maintenance 24
Errors, malfunctions and their remedy 24

8750 - 1
INSTALLATION

Short Operating Instructions

for commissioning the

The Flow Control System FMR Type 8750

Note
These short operating instructions describe in brief the most important steps in the installation
and commissioning of the Flow Control system FMR Type 8750.
The system Type 8750 consists of a control valve Type 2712, a TopControl Continuous Type
8630, two pressure sensors Type 8323 and optionally a temperature transmitter.
The present short operating instructions are limited to the essential steps for
- installation, commissioning, configuration and self-optimization,
- error messages, malfunctions and error elimination.
For more advanced or detailed questions, please use the more detailed documents supplied
on the CD or to be found on the Internet.

2 - 8750
 INSTALLATION

Symbols

The following symbols are used in these operation instructions:

ATTENTION! Indicates information that must be followed. Failure to do this could

endanger your health or the functionality of the device.

NOTE Indicates important additional information, tips and recommendations.

Intended use
The Flow Control System Type 8750 shall be used exclusively for the control of volumetric
flow or flow velocity in gaseous media. Only the medium stipulated in the contract shall be
allowed to enter the device. Before putting into operation, changes in the medium must be
discussed and clarified with us. The device shall be operated only at the values stated in the
chapter „Technical Data“ and given on the rating plate.

The safety devices on the system shall under no circumstances be circumvented. The
required personal protective equipment must be worn and the accident prevention regulations
complied with. The components installed at the time of commissioning shall not be
disassembled without a specific written work instruction.

Read carefully through all chapters of these short instructions and the operating instructions
for the components of this system, which are to be found on the CD or on the Internet under
www.buerkert.com
Observe the notes given in the chapter „General Safety Notes".

The device shall be operated exclusively by trained specialists who have been instructed by
us. Electrical work on the device shall be performed only by a trained, qualified electrician
who has also been instructed by us. During electrical work, the main switch must be switched
off and secured.

Conversions and modification to the device on the user's initiative are prohibited for safety
reasons. On exchange of faulty or worn parts, only original spare parts shall be used.

The work instructions in the individual chapters must be complied with and the safety notes
observed under all circumstances. If work instructions are not followed in the exact sequence,
or safety notes or symbols are ignored, all warranties will become void.

8750 - 3
INSTALLATION

Safety notes

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

operating the device.
• Installation and maintenance work are only allowed by qualified
personnel using suitable tools.
• Observe the current regulations on accident prevention and safety
for electrical devices.
• Before intervening in the system, always switch off the power
supply.
• Note that in systems under pressure, piping and valves may not be
loosened.
• Take suitable precautions to prevent inadvertent operation or
damage by unauthorized action.
• After interruption of the electrical or pneumatic supply, make sure
the process is restarted in a well-defined, controlled manner.

Transport, storage

ATTENTION! Transport and store the appliance in its original packing only.

Disposal

ATTENTION! When disposing of the appliance, observe the national standards for
refuse disposal.

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 INSTALLATION

Description

The Flow Control System FMR Typ 8750 was developed for the control of propellent air for
the pneumatic conveyance of pourable solid media (e.g. plastics granulates) over long
distances. Following its success in this application, the FMR was used in the control of
combustion air and gases (e.g. combustion in ceramic furnaces) and for the control of the
propellent (e.g. air, nitrogen) in pigging installations.

The system consists of

- a control valve Type 2712 with TopControl Continuous Type 8630
- two pressure sensors Type 8323
- and optionally a temperature transmitter.
These components together form a module.

• All operating functions are executed via 3 function keys.

• The operating menu of the FMR is delivered with factory settings.

NOTE Change the factory settings of the operating menu only if required by
concrete process conditions.

• The real flow characteristic curve for the current control valve is stored point-for-point in 5
% steps in the memory of the controller.

NOTE Before first commissioning, check the factory settings and set the
process parameters that are still open.
With these settings, the controller parameters are adapted to system
behaviour in the subroutines AUTO and Process-TUNE.

• The sensors are built into the connecting tubes to the valve.
• To cover a wide variety of control applications, a broad spectrum of nominal diameters
and seat combinations is available.
• The valve seats may be exchanged as required.

ATTENTION! On assembly of the module, the intake sections to EN ISO 5167-1

must be observed (shown in the section "Intake sections to
EN ISO 5167-1").

• The outlet sections are already integrated in the system.

• The pressure drop over the control valve (acting as a restriction) is measured
continuously by the two pressure sensors. This pressure difference and the valve flow
characteristic are the parameters for determination of the volumetric flow through the
control valve, i.e. for the process value. This measured value is compared with the
setpoint, evaluated in a PID controller and set on the positioner as the new setpoint.

8750 - 5
INSTALLATION

Sequence of steps from assembly up to commissioning of a system with FMR

ATTENTION! Inform yourself on the intended use and safety notes; comply with
internal works safety instructions and accident prevention regulations;
make ready any safety equipment required.

• Check the operating conditions against the technical data for the system Type 8750
delivered.

ATTENTION! Before starting assembly, disconnect the existing system from the
voltage supply and release the pressure.

• Assemble the control system in the existing system in observance of the required intake
section; check the connection points for leaktightness (pressure test, etc.).
• Wire the electrical cable connectors according to PIN allocation and make these
connections.
• Make the control air connection and attach a silencer to port 3 if necessary; check the
control connection for leaktightness.
• Connect the operating voltage and control air.
• Inform yourself about the operating strategy and the functions of the operating keys.
• Check the factory settings of Type 8750 and carry out the necessary process dependent
settings in the operating menu.
• Start X.TUNE (AUTOTUNE) for determinaton of the parameters for the positioner.
• Set all parts of the system to the operating condition (control air, operating voltage,
external signals, medium flow, etc.).
• Prepare PROCESS TUNE for automatic determination of the controller parameters.
Step 1 Activate the menu item for PROCESSTUNE (P.CO TUNE \ P.TUN ON).
Step 2 Determine a value for the setpoint step.
Step 3 Check the starting value for the setpoint step and if necessary set
this starting value more exactly.
Step 4 Enter the setpoint step by hand. When the entry is finally confirmed, the
function PROCESS TUNE is started automatically.

• Check the orderly running of PROCESSTUNE.

• Register and evaluate the control results of the system with the FMR.

NOTE All necessary operating steps for processing the step sequence are
described in these operating instructions. For more advanced
questions, please use the documents supplied on the CD or the
Internet.

6 - 8750
 INSTALLATION

Technical data of the FMR Type 8750

Valve housing material Stainless steal-investment casting 316L
Flange material stainless steel 1.4301
Actuator material polyamide (PA)
TopControl housing material Noryl (PPE/PA)
Packed gland (with silicone grease) PTFE-rings (with spring compensation)
Control plug parabolic geometry for equipercentile characteristic
Seat reduction (orifices) various Kvs-values for each connection size
Intake and outlet sections to EN ISO 5167-1
Other parts contacting media stainless steel 1.4571
Media
Standard air and other gases
on request steam and liquids
Media temperature 0 to +80 °C
Ambient temperature -10 to +50 °C
Media pressure 0 to 6/10 or 16 bar
(depending on the pressure sensor range)
Control medium instrument air to DIN ISO 8573-1
Dust content • max. 40 µm particle size
Particle density • max. 10 mg/m³
Pressure dew point • -20 °C
Oil concentration • max. 25 mg/m³
Intrinsic air consumption 0 l/min
Control air temperature 0 to +50 °C
Control air pressure 5.5 to 7 bar (DN15 to DN 65)
5 to 6 bar (DN80 and DN100)
Components
Control valve Type 2712, SFA or SFB
Pressure sensors Type 8323
TopControl Continuous Type 8630 with process controller
Temperature transmitter e.g. Type 1571, 0 to +150 °C
Pressure measurement range 0 to 6/10/16 bar, other ranges on request
Operating voltage 24 V DC
Residual ripple 10 %, not industrial DC!
Electrical connection
Operating voltage circular connector, male, M12
External signals circular connector, male, M16
Setpoint specification 0/4 to 20 mA or 0 to 5/10 V
Type of protection IP65 to EN 60529
Display LC display, 8-digit
Operating panel 3 function keys
Options • binary input
• analog feedback
• binary outputs (alarm)
• bus communication (ProfibusDP or DeviceNet)
Process connections flange to DIN EN 1092-1, ANSI, JIS; welding ends
to ISO 4200, DIN 11850 S2, BS 4825, ASME
Nominal diameters DN15 to DN100, in the usual steps
Sensor assembly P1, P2, T G 1/2 sleeve in the FMR tube
Measurement section to DIN EN 60534-2-3

8750 - 7
INSTALLATION
Dimensions
An FMR is delivered completely assembled with wired pressure transmitter lines
(the version shown was assembled without a temperature transmitter).

TopControl Type 8630

actuator, control valve Type
2712
cable from pressure transmitter
to TopControl Type 8630
pressure transmitter Type 8323
flange to DIN EN 1092-1

ATTENTION!
On assembly, be sure to
connect an intake
section to EN ISO 5167-
1 upstream. The
required outlet sections
are already integrated
into the FMR (6 x DN).

DN Pipe connection [mm] L [mm] HG mm] ØE [mm]

15 330 391 101
25 500 389 101
40 700 481 127
50 800 518 157
65 1000 547 157
80 1200 623 261
100 1400 633 261

Intake section to EN ISO 5167-1 Action diagram of the FMR

For process parameters on the FMR, the

volumetric flow through the valve or the flow velocity
of the medium at the defined pipe as reference may
be selected with the operating software (cf. menu
item P.CONTRL\P.CO SCAL).

8 - 8750
 INSTALLATION
Installation of an FMR in a system
• Any orientation of installation of the FMR may be chosen, but the TopControl should
preferably be above.

ATTENTION! Observe the direction of flow (arrow on the valve fitting); the inlet flow
to the control valve may as a general rule only be under the seat.

• In order to avoid turbulent flow at the pressure transmitter, a suitable intake section must
be provided immediately upstream of each FMR (dimensions to EN ISO 5167-1 as per
sketch); the outlet section is already integrated into the FMR.

ATTENTION! Thoroughly clean all connection points prior to installation.

• Make sure that piping is well aligned and that the FMR is installed without stress. The
piping must be fixed or supported as necessary.

ATTENTION! Make sure that all connections are leaktight.

Connection of the control air at the TopControl

Port 1 Control air connection

5.5 – 7 bar for DN 15 to DN65
5 –6 bar for DN80 and DN100
Port 21 Connection for single-acting actuator (already
mounted in the factory)
Port 22 not connected
Port 3 Connection for exhaust air, use optional silencer
G 1/4 G 1/8 G 1/8 G 1/4

Electrical connections
(see PIN allocation tables for circular male connectors M16 and M12)
• The electrical connections to the FMR are made with circular connectors at the connector
plate of the TopControl.
• The signal connections between the pressure transmitters and the TopControl have
already been made in the factory (with M8 circular connectors).
• In the case of the FMR version with optional temperature transmitter, the signal
connections have also been made in the factory with M8 circular connectors.
• If signals go out from the FMR, an M16 circular connector wired as per PIN allocation plan
is required. The M16 circular connector may be obtained from Bürkert.
• Wire an M12 circular connector as per PIN allocation plan for the power supply. The M12
circular connector may be obtained from Bürkert.
• Make the signal connection to the TopControl with the M16 circular connector.
• Make the connection to the power input of the TopControl (e.g. from a power supply unit)
with the M12 circular connector.

8750 - 9
INSTALLATION

Electrical connections of FMR Type 8750

PIN allocation on FMR Electrical connector plate on FMR

Circular plug Circular plug M16 Circular plug M12
M16, 12-pole,
connection of
signal inputs and
signal outputs
(from and to
SPC)
Circular plug
M12, 4-pole,
connection of
operating voltage Circular plug M8 Circular plug M8
24 V DC TE (technical earth)
The transmitter has been connected with circular plug M8 in the factory.

PIN Contacts of circular male connector M16 Signal level

A Setpoint GND GND
B Setpoint + 0/4 ... 20 mA or 0 ... 5/10 V
C Analog position feedback + 0/4 ... 20 mA or 0 ... 5/10 V
D Analog position feedback GND GND
E Binary output 1 + Low = 0 V; High = 24 V
F Binary output 2 + Low = 0 V; High = 24 V
G Common GND for binary outputs GND
H Binary input + Low = 0 ... 5 V; High = 10 ... 30 V
J Binary input GND GND
K Not used ---
L Not used ---
M Not used ---

PIN Contacts of circular male connector M12 Comment

1 +24 V DC (± 10 %) max. residual ripple 10 %
2 Not used ---
3 GND GND
4 Not used ---

10 - 8750
 INSTALLATION

Prefabricated cables as accessories

Cable with M16 socket:

Order no. 651652: 2 m cable with M16 socket, 12-pin
Order no. 651653: 5 m cable with M16 socket, 12-pin

PIN Signal Wire colour

A Nominal value GND white
B Nominal value + (0/4–20 mA or 0–5/10 V) brown
C Analogue position feedback + green
D Analogue position feedback GND yellow
E Binary output 1 grey
F Binary output 2 pink
G Binary output GND blue
H Binary input + red
J Binary input GND black
K, L, M not used not used
All wires feature wire end ferrules.

Cable with M12 socket:

Order no. 918038: 5 m cable with M12 socket, 4-pin

PIN Signal Wire colour

1 +24 V Brown
2 Not used White
3 GND Blue
4 Not used Black
All wires feature wire end ferrules.

8750 - 11
 Kv value table for FMR versions (data for valve stroke and flow in %)
The set of values measured for the corresponding orifice (trim & plug) is stored in the FMR memory in the factory.

12 - 8750
Valve stroke POS [%] 0 5 10 15 20 25 30 35 40 45 5 55 60 65 70 75 80 85 90 95 100
Valve version 0
DNpipe DNorifice Kvs Flow Kv in [%] for the above positions of the valve stroke in [%]
[mm] [mm] [m³/h]
INSTALLATION

8.0 2.1 0.0 3.3 3.8 4.8 5.2 5.7 6.2 7.6 9.0 11.0 12.9 16.2 20.5 24.8 30.0 37.6 45.2 58.1 76.2 90.5 100.0
15 10.0 3.1 0.0 2.9 3.5 4.2 4.8 5.5 6.1 7.7 10.0 12.6 15.8 19.7 24.2 29.7 35.5 44.2 54.8 67.7 80.6 92.6 100.0
15.0 4.3 0.0 3.3 4.0 4.4 5.1 6.5 8.1 9.8 12.1 15.1 18.6 22.8 27.9 34.4 41.9 51.2 62.8 74.4 86.0 94.4 100.0
15.0 5.3 0.0 2.6 3.2 3.6 4.2 5.1 6.6 8.1 9.8 12.1 15.1 18.5 22.6 27.5 34.0 43.0 54.7 66.0 77.4 88.7 100.0
25 20.0 7.2 0.0 2.8 3.5 3.9 4.3 5.3 6.5 7.9 9.7 12.2 15.3 18.5 22.2 27.5 34.7 42.8 52.8 63.9 75.0 87.5 100.0
25.0 12.0 0.0 2.9 3.2 3.9 5.4 6.8 8.3 10.2 12.5 15.0 18.3 22.7 28.3 35.3 42.5 49.6 58.3 67.9 78.3 89.2 100.0
25.0 13.6 0.0 2.9 3.7 4.5 5.5 6.6 8.1 10.1 12.5 15.4 19.1 23.0 27.9 34.1 41.2 49.6 58.8 68.4 78.7 89.0 100.0
40 32.0 20.2 0.0 2.4 3.0 3.5 4.2 5.1 6.4 8.2 10.4 12.9 15.8 19.0 22.8 27.8 34.2 43.3 54.5 64.4 74.3 85.6 100.0
40.0 23.8 0.0 2.5 2.9 3.7 4.6 5.7 7.1 9.0 11.3 13.7 16.8 20.8 25.2 31.5 38.7 47.5 58.0 67.2 76.5 87.0 100.0
32.0 21.0 0.0 2.3 2.9 3.5 4.3 5.1 6.2 7.9 10.0 12.5 15.2 18.3 21.9 26.7 32.9 43.0 55.2 65.5 76.2 87.4 100.0
50 40.0 24.6 0.0 2.4 2,8 3.3 4.1 5.4 6.9 8.5 10.6 13.1 16.3 19.8 24.0 29.8 37.4 47.2 56.9 66.3 76.8 87.8 100.0
50.0 37.0 0.0 2.4 3.0 3.9 5.1 6.4 7.8 9.8 12.2 15.0 18.4 22.7 28.4 34.9 41.9 50.7 59.5 68.9 79.2 89.2 100.0
40.0 17.5 0.0 2.6 3.7 4.6 5.4 6.3 7.4 8.9 10.9 13.2 16.0 19.2 22.9 26.9 31.4 37.3 44.6 53.9 66.9 82.3 100.0
65 50.0 26.0 0.0 2.7 3.8 5.0 6.2 7.6 9.2 11.2 13.5 15.9 18.8 22.5 26.5 31.8 37.7 45.2 54.2 64.5 76.5 88.5 100.0
65.0 52.0 0.0 1.5 2.5 3.3 4.0 4.9 6.2 8.0 10.6 13.5 17.5 22.3 28.3 37.1 47.1 60.6 72.3 80.6 87.7 93.8 100.0
50.0 42.0 0.0 2.0 2.4 2.9 3.6 4.5 5.5 6.8 8.3 10.0 11.9 14.3 16.9 20.5 25.0 30.7 38.1 46.8 59.5 76.4 100.0
80 65.0 70.0 0.0 2.0 2.4 2.9 3.6 4.4 5.4 6.7 8.1 9.7 11.7 14.2 17.4 22.0 27.9 36.1 46.4 58.0 71.4 85.7 100.0
80.0 100.0 0.0 2.1 2.6 3.2 4.2 5.5 7.0 8.6 10.5 12.9 16.0 20.0 25.0 31.9 40.0 49.5 60.0 71.0 83.0 92.4 100.0
65.0 75.0 0.0 1.9 2.3 2.8 3.5 4.2 5.1 6.2 7.6 9.1 11.1 13.7 16.8 21.2 26.7 33.6 42.7 54.0 68.0 83.3 100.0
100 80.0 115.0 0.0 1.8 2.3 2.9 3.7 4.8 6.1 7.6 9.6 12.0 14.8 18.3 23.0 30.0 38.3 47.4 56.5 66.3 77.4 88.5 100.0
100.0 140.0 0.0 2.3 2.8 3.3 4.1 5.1 6.4 7.9 9.6 11.8 14.6 18.4 22.9 29.1 36.4 46.1 59.3 72.5 84.3 93.3 100.0
 INSTALLATION

Operating levels of the FMR

Operation of the FMR is done via the process operating level and via the configuration level.

The process operating level is active after
switching on the device. In this level, one can
switch between the AUTOMATIC and MANUAL
modes by briefly pressing the manual/automatic
key. In the AUTOMATIC mode, the position or
process control runs; in the MANUAL mode, the
valve may be opened or closed by hand. To
change to the configuration level, one must press
the M/A key for 5 s.
In the configuration level, the basic
functions and, if needed, supplementary
functions are specified on first
commissioning. During configuration,
the process falls into a stationary state
with the parameters immediately prior to
switchover. Return to the process level
is done from the menu item END.

Display and function keys

Key functions in the process
FMR operation with operating level for manual
3 function keys (from automatic with to manual)
MANUAL/AUTOMATIC key open valve
LED (yellow)
close valve
Manual → LED off
Auto → LED flashes + fast opening
up down Arrow keys up / down + fast closing

Key functions in the configuration level

With key you scroll up; with key you scroll down or change the settings (values,
alternative parameters).
With key you change between the menu levels, call up current settings in a menu item,
confirm entries, make changes and return to the menu item.

Factory settings and required operator settings

(factory settings are shown in italics, underlined, in the following operating menu)
Prerequisites - FMR is installed and connected;
- operating voltage and control pressure are switched on.
Procedure for checking and setting
After the operating voltage is switched on, there appears for ca. 5 sec the display EEPROM;
after this, the system automatically activates the process operating level with the display
POS 0.
The yellow LED in manual-automatic key flashes and at the upper edge of the display, an
apostrophe (') rund from left to right.
To get to the configuration level, one presses the manual/automatic key until the main
menu item ACT.FUNC is shown in the display (see following program sequence).

8750 - 13
INSTALLATION

Program sequence on commissioning

Menu item Required Explanations / Remarks
settings
(factory settings)
EEPROM After ca. 5 sec, Program parameters are loaded from an EEPROM;
automatic then the process operating level is active; the yellow
initialization LED in key flashes;
POS 0 POS displayed on the display, an apostrophe (') runs from left to
right; change to configuration level by keeping key
depressed until ACT.FUNC appears on the
display
ACT.FUNC FUNC SNGL Program stands in the first main menu item
ACT.FUNC. The operating mode of the actuator
was already set in the factory (single-acting= SNGL;
double-acting = DOUB); change if necessary with
an arrow key; confirm setting with and return to
ACT.FUNC
INPUT INP 4'20A The standard signal set 4'20A (4 to 20 mA) may be
changed with an arrow key
(choose between 4'20A; 0'20A; 0' 10V and 0'5 V);
confirm settings with and return to INPUT
CUTOFF CUT ⊥ 0 Tight-closing function of the process controller on
CUT T 100 reaching the value in %; lower ⊥ and upper T values
may be changed with the arrow keys;
confirm setting with and return to
CUTOFF
X.TIME T.OPN 60 Setting of the floating time between opening and
T.CLS 60 closing is performed by Autotune; manually, the
arrow keys may be used to set a value from the
range from 1 to 60 s;
confirm setting with and return to X.TIME
P.CONTRL Program stands in the main menu item P.CONTRL;
the required process controller parameters are now
set

P.CODBND DBND 1.0 Specify a dead band for the actuating signal, within
which the the controller does not react; change the
position with and the values with arrow keys;
confirm setting with and return to P.CO DBND
P.CO PARA KP 1.0 In the factry, the process controller is set to a P-
TN 999.9 controller; the final controller parameters are
determined later by Processtune; change the position
TV 000.0
with and the values with the arrow keys; confirm
X0 0
setting with and return to P.CO PARA
P.CO SETP SETP INT Set setpoint to internal (INT) or external (EXT);
confirm setting with and return to P.CO SETP

Further to P.CO INP

14 - 8750
 INSTALLATION

P.CO INP INP P1'P2 Signal type P1'P2 (two pressure sensors),
alternatives to 4‘20A with ;
confirm setting with and return
to P.CO INP
P.CO FILT FILT 0 With arrow keys set a filter value
from 0 ... 9 for the process input; 0 = smallest effect;
9 = greatest effect; recommended setting: 5 or 6;
confirm setting with and return to P.CO FILT
P.CO SCAL DP 1 DP = decimal point for (0, 1, 2, 3) digits after the
PV⊥ 000.0 point; PV = process value in m³/h; PV⊥ = lower
scaling value (here 0 m³/h); is allocated to the
PVT100.0 smallest input signal (here 4 mA);
PVT = upper scaling value (here 100 m³/h); is
allocated to the largest input signal (here 20 mA);
PVT must be actualized by the operator according to
the geometry of the control valve.
SP⊥ xx.xx With SETP INT, menu item SP is suppressed
SPT xx.xx (only active with SETP EXT); SP = process setpoint
in m³/h
SP⊥ = lower scaling value; is allocated to the
smallest value of the standard setpoint signal used
(0/4 mA; 0 V);
SPT = upper scaling value; is allocated to the
greatest value of the standard setpoint signal used
(20 mA; 5/10 V)
P.TYPFLOW Select type of controlled variable; with the controlled
UNITM3/H variable, the dimension is also specified;
alternatives: TYP FLOW (flow in m³/h) or TYP VELO
(flow velocity in m/s)
TEMP MAN Set with arrow keys, whether media temperature is
TEMP 20.0 to be measured manually (TEMP MAN) or by
sensor (TEMP SENS); change of temperature (here
+20 °C) is possible with arrow keys
DENS 1.293 Medium density required for flow control; here
DIAM 0015 density for air of 1.293 kg/m³; specify DIAM for
piping diameter (here 15 mm), only possible with
TYP VELO active; confirm last setting with ;
program jumps to P.CO SCAL
P.CO TUNE P.TUN ACT The function P.TUN ACT must be active at the start
P.TYPFLOW of PROCESSTUNE, only then can it be carried out
after completion of the required parameter entries;
change with arrow keys;
with select the controlled member FLOW or
N.DEF (both define a PI controller)
with confirm settings and return
to P.CO TUNE

Further to P.CO KV

Further to SIG--ERR

8750 - 15
INSTALLATION

P.CO KV KV FACT At KV FACT, the valve characteristic entered in the

KVS 2.10 factory, as shown in the Kv-value table, is
activated; alternatively, a user-specific
0 000.0 characteristic may be entered under KV USER;
5 003.0 Note: with the command SETFACT, all manually
10 004.0 changed characteristic values are reset to the
... factory settings;
95 088.0 With further to display of the stored KVs-value
100 100.0 (KVs-value = max. possible flow rate: here 2.10
m³/h); with further to display of the stored KV-
valve characteristic in %, referred to the KVs-value
(= KV/KVs in [%]); the valve characteristic is
displayed in 5% steps (cf. KV table); a change of
value is only possible with KV USER; after display
of the 100 % point,
with return to P.CO KV
P.CO LEAK LEAK D’ACT Deactivate the air leak compensation
LEAK ACT Activate the leak compensation
LEAK MEAS Background: during transport of pourable solids,
Taste there arises at a rotary valve an air leakage
gedrückt halten dependent on the pressure. The air flow through
bei Anzeige the controller unit is the sum of this leakage and
TUNE 5, 4 …1,0. the air flow of the conveying pipe. QFMR = Qair leak
Es folgen die + Qconv.path
Anzeigen Reading in the air characteristic once with the
LEAK IN conveying pipe closed enables the air leakage to
LEAK PO be compensated during conveying, increasing the
LEAK OPN precision of flow control.
LEAK PAR und The program for automatic registration of the
LEAK END leakage characteristic is started with P.CO LEAK
→ LEAK MEAS
Then hold the key depressed for 5 sec.
NOTE: to break off leakage measurement, press
key + simultaneously and select LEAK BRK.
LEAK CHAR Display leakage characteristic
P.CO END With to menu item P.CO DBND or
with jump back to main menu item P.CONTRL

Further to SIG--ERR

16 - 8750
 INSTALLATION

SIG--ERR Configuration for error recognition in the internally

measured or external added signal level

ERR P.INP P.INP ON Process value signal error recognition (with

SPOS OFF P.INP OFF, no automatic error display);
with SPOS OFF, approach to safety position if
signal error occurs; display of the corresponding
error no. (see also errors / malfunctions);
ERR INP INP OFF With INP OFF, no process-setpoint signal error
recognition occurs if an error occurs; this setting is
sensible with internal setpoint specification SETP
INT
ERR END With to menu item ERR P.INP or
with jump back to main menu item
SIG--ERR
CAL.USER Configuration for detection of errors in the internally
measured or externally applied signal level.

(CAL POS)
(CAL SP)
(CAL PV)
CAL P1 P1 4 MA Calibration of the transmitter inputs at the flow
CAL P2 P1 20 MA controller (4 ... 20 mA)
At the input to be calibrated (p1/p2/temperature)
apply 4 mA and confirm the value with the key;
then apply 20 mA and again press the key.
At the input p1/p2
4 mA corresponds to a pressure of 0.0 bar (rel.)
20 mA corresponds to a pressure of 10.0 bar (rel.)
or the full scale value set under CAL PLIM.
At the temperature input
4 mA corresponds to a temperature of 0 °C
20 mA corresponds to a temperature of 150 °C
or the full scale value set under CAL TLIM.
CAL PLIM P1 MIN xxxx Setting the sensor range
P1 MAX xxxx 1.Enter the lower pressure/temperature value;
it corresponds to the transmitter signal 4 mA.
2.Enter the upper pressure/temperature value;
it corresponds to the transmitter signal 20 mA.
The values must lie withing the following ranges:
P MIN -1.01 ...15.0 bar (relative)
P MAX 0.0 … 16.0 bar (relative)
T MIN and T MAX 0 … 150 °C

Further to CAL P1’P2

Further to ADDFUNCT
8750 - 17
INSTALLATION

CAL P1’P2 P1 xxxx Balancing the pressure transmitter

P2 xxxx The pressure transmitters p1 and p2 may be
calibrated to increase the measuring precision at
small pressure differences.
For this purpose the conveying pipe behind the
process valve (FMR) must be closed off and the
controller unit pressurized with a constant pressure.
Calibration of the zero point:
pressure < 10 % of the sensor range,
Calibration of the upper calibration value:
pressure > 55 % of the sensor range.
Changeover of dislay between p1 / p2 with .
By pressing the key the value shown is
confirmed and the other value made equal to it.
NOTE: if the pressure is between 10 % and
55 % or a deviation of p1 from p2 of> 1.5 %exists,
the procedure is aborted and the message
P1P2 ERR displayed.
CAL TEMP TEMP 4 MA (see CAL P1 / CAL P2)
TEMP 20 MA
CAL TLIM T MIN xxxx (see CAL PLIM)
T MAX xxxx
CAL FACT Hold depressed Reset the settings made under CAL.USER to the
key on display factory settings.
of
FACT 5, 4, 3, 2, 1.
ADDFUNCT CHARACT Main menu item for selection of supplementary
up to functions
Recommendation: please jump over at first this
ENDFUNCT
menu item with key for checking the factory
settings and for execution of first commissioning.
Program points already transferred from
ADDFUNCT to the main menu are prefixed with a *.
X.TUNE Hold depressed Execution of AUTOTUNE for determining the
key on display parameters for the positioner; during execution of
of TUNE 5, 4, 3, 2, X:TUNE, the currently running worksteps are
1; there follow the displayed;
displays The
before X.T symbolizes a rotating bar and

X.T A I—P; shows that the program is running;

X.T TCLS and after completion, the display shows TUNE-END; in
TUNE-END or case of error, X.ERR X (X = 1 ... 7) is shown (see
X.ERR 1 ... 7 errors / malfunctions)
P.Q'LIN Hold depressed At first, please jump over with ! P.Q'LIN serves
key for at least to improve the control quality if the control behaviour
5 s until the after PROCESSTUNE is insufficient (see also
countdown runs Operating Instructions 8630)

Further to END I.00

18 - 8750
 INSTALLATION

END I.00 Automatic With , jump back to the main menu item
transfer of all ACT.FUNC;
values entered to With , all values previously entered are stored in
the memory and the memory and the program jumps automatically
jump back into the via EEPROM back to the process operating level
process operating POS 0 and the yellow LED flashes; the
level to prerequisites are now fulfilled for execution of
return to POS 0 PROCESSTUNE (see following box).
ACT.FUNC

8750 - 19
INSTALLATION

Program function P.CO TUNE (PROCESSTUNE)

To assure good control behaviour, the controller parameters must be adapted optimally to a
controlled member. Good control behaviour is characterized by a short floating time, small
overshoot range and adequate damping.
The process controller of the FMR, together with the positioner, controls as a function of the
pressure difference the flow rate [m³/h] or velocity [m/s] of the medium. The process controller
was preset in the factory with KP = 1; TN → ∞ and TV = 0 (i.e. as a P-controller). With these
parameters, the control does not function!
With the start of the program part P.CO TUNE, the controller parameters fitting the controlled
member are determined by a modified Ziegler/Nichols procedure. For this purpose, under
operating conditions, a single setpoint step is initiated and the response determined. In
evaluation of this response, the program determines automatically the most favourable
controller parameters for the present controlled member. These are transferred to the
program and replace (overwrite) the preset parameters.

Prerequisites for starting P.CO TUNE (PROCESSTUNE)

• Checking of the factory settings and entry of the process specific parameters have been
completed.
• X.TUNE (AUTOTUNE) has been run successfully through to TUNE-END.
• The entire system is fully operational, i.e. control air, operating voltage, external signals,
medium and any bulk goods to be transported have been activated.
• A process setpoint (setpoint step), which is still to be entered manually, has been
determined (see also the note in the following box).

NOTE On the „compatibility“ of the external and internal setpoints, and that to
be newly entered.
With the setting SETP EXT, the external setpoint SP is suppressed
when PROCESSTUNE is activated in favour of the setpoint step SP
(SP-Tune) to be newly entered, for the duration of this function. With
the setting SETP INT, the setpoint to be newly entered serves as SP-
Tune for the setpoint step, and after execution of PROCESSTUNE as
the process setpoint SP for subsequent operation in the automatic
mode.

Preparation for entry of a setpoint step SP

A prerequisite the entry of SP is the activation of the function PROCESSTUNE (P.TUN ON).
Starting point for checking or correction of this setting is the process operating level POS
0, automatic mode, i.e. the yellow LED in key flashes and the apostrophe (') in the display
runs from left to right.
 Press simultaneously the keys and ;
 The display now shows P.TUN ON or P.TUN OFF;
 With key , set P.TUN ON and
 With key , confirm the correctly set function;
 After confirmation the program stands at SP ≡ XXX.X.
SP is the setpoint still to be entered (in m³/h or m/s); it corresponds to the SP-Tune in the box
dealing with the starting value.
The display SP flashes and the apostrophe (') runs from left to right in the display. The 3
horizontal bars ≡ behind SP symbolize the fundamental readiness for starting of
PROCESSTUNE.

20 - 8750
 INSTALLATION

Explanations on the starting value

The setpoint step is realized between a starting
value and the process-setpoint SP to be specified
(SP-Tune). The height of the setpoint step must be
determined in relation to the process
(setpoint step = SP-Tune minus starting value).
The starting value used is the measured real
momentary value of the controlled variable PV.
This starting value depends directly on the
momentary valve position and can in the automatic
mode be displayed with in m³/h. If it differs very
little from the planned setpoint SP, it should be
changed manually. For this purpose, the program is switched with key into the manual
mode (LED off). With key or , the valve position can now be suitably changed.
With key , return to the automatic mode; show starting value for checking with . If the
result is unsatisfactory, modify the starting value.

Possible display of process values in the automatic mode

Apart from the starting value (= process value), by pressing the arrow keys or in the
automatic mode (yellow LED flashes), the value shown in the following table may be dis-
played from the menu item SP ≡ XXX.X
Value Remark Value Remark
SP process setpoint still to be entered TEMP Interior temperature in the TopControl
in °C or °F
PV starting value or process value of the M.TEMP Medium temperature in °C or °F;
controlled variable in m³/h or m/s Option with temperature transmitter
POS actual position of valve actuator in % P1 pressure before valve in bar
(∆P = P1 - P2)
CMD setpoint position of valve actuator in % P2 pressure after valve in bar

Entering the setpoint step and initiating PROCESSTUNE

Before initiation of the function PROCESSTUNE, the starting value must already be properly
set for the process. The program is in the automatic mode (yellow LED flashes),
menu item SP ≡ XXX.X.
On setting a setpoint step suitable for the process, PROCESSTUNE is initiated.
For this purpose, entry of a process setpoint SP (SP-Tune) is required:
 Hold one of the arrow keys or depressed for at least 3 s.
 After release of the key, the first digit X of the process setpoint SP ≡ XXX.X flashes.
 Enter at the flashing digit X with key or the value for this digit (in m³/h or m/s,
depending on the configuration).
 Confirm the value set at this digit with key .
 The program moves automatically to the next digit.
 Enter in the same manner the value for this digit.
 After confirmation of the value for the fourth digit with , the now completely entered
process setpoint SP (SP-Tune) is transferred to memory as the final value for the setpoint
step and the function PROCESSTUNE starts automatically.
 While the function PROCESSTUNE runs, the display
P.TUNE is shown (
symbolizes
here a rotating bar).
 After completion of PROCESSTUNE, the program assumes the optimized controller
parameters and returns by itself to the automatic mode (yellow LED flashes).
 The process controller now works with the newly determined controller parameters.

8750 - 21
INSTALLATION

Evaluation of the control results after commissioning of the system

After successful completion of PROCESSTUNE, the system runs with the FMR in the
automatic mode. With reference to the control results, an evaluation of the results obtained is
now made.
A) The control results correspond to the technical requirements. In this case no further
measures are required.
B) The control results deviate from expectations. In this case you should initiate measures
for improvement of the control behaviour.

Measures for improving the control behaviour

1. Carry out a linearization of the process characteristic with the routine P.Q'LIN and repeat
P.CO TUNE.
2. Correct the valve characteristic point by point, deviating from the characteristic shown in
the Kv-value table, which is stored in the program. On correction, the values originally
stored in the program memory are overwritten.
3. Select some other nominal width of valve seat from the Kv-value table or data sheet. For
this, the valve must be converted or exchanged.

Program function P.CO.LEAK (leak detection). Only for conveyor system’s

applications.
Boundary conditions for the reading-in of the leakage characteristic
For exact measurement of the leakage, the system should be started up in the normal mode.
However, the following exceptions apply:
• The conveying pipe must be closed off behind the components causing the leak.
• The material to be transported is omitted.

ATTENTION! • In the case of pneumatic conveying of pourable solids with a rotary

valve, the following must be observed:
• The conveying pipe must be closed off behind the rotary valve.
• The rotary valve must be empty and run at the nominal rpm.
• Measures for sealing the system (e.g. blocking air that enters from
above into the rotary valve) must be connected.
• The compressor must be switched on.

Succession
• The control valve is closed.
• After 10 sec settling time, the admission pressure at the controller unit (FMR) is
registered.

NOTE Scaling of the x-axis of the leakage characteristic is based upon this
pressure value. The upper limit is this value times a factor of 0.85.
Up to 21 reference points are determined.
Example: at an admission pressure of 2.0 bar, the characteristic curve
is obtained from 0 to 1.7 bar in 85 mbar steps.

• The control valve is slowly opened in a ramp time of 60 sec.

22 - 8750
 INSTALLATION

• Parallel to this, the conveyance pressure (pressure at the outlet side of the FMR) is
monitored. For each reference point of the characteristic, the conveyance pressure and
the air flow are registered.
• Reading in is complete when after 60 sec the control valve is fully open, or the
conveyance pressure previously reaches the upper limit of the scaling.
• Air leakage compensation is now activated. The process value is now obtained from the
difference between the measured air flow and the air leak rate calculated from the
characteristic:
Qconv. path = QFMR – Qair leak

Deactivate leakage characteristic

Activate leakage characteristic

Start automatic determination of the leakage characteristic

Show the leakage characteristic display.

Reference points are displayed alternately as conveyance pressure
in mbar and air flow or conveyance speed in m3/h or m/s
respectively.
Display Description
TUNE 5 Countdown from 5 to 0 to the start of leakage determination
TUNE 4
:
TUNE 0
LEAK IN Display of the momentarily running phase of leakage determination
LEAK P0 (progress is indicated by a rotating beam at the left hand edge of
LEAK OPN the display)
LEAK PAR
LEAK END Display flashes. Leakage determination successfully completed
L.ERR X Display on occurrence of an error
(Display on the right: error number, see chapter Maintenance and
Troubleshooting in the controller manual)

8750 - 23
INSTALLATION

Maintenance
The FMR is to a large extent maintenance-free when used as intended.

ATTENTION! Make sure that the FMR does not come into contact with aggressive
media.

If the exterior becomes soiled, FMR should be cleaned only with compatible cleaning agents.
In case of doubt, make a test of compatibility.

Error and malfunctions of the FMR

General error messages
(shown only with external setpoint SETP EXT and activated SIG ERR)
Display Cause of error Remedy
INT.ERROR Internal error not possible, device faulty
SP FAULT Signal error, setpoint check signal
Process controller
P1 FAULT Signal error, actual value P1 check signal
Flow Control System
P2 FAULT Signal error, actual value P2 check signal
Flow Control System
TMP FAULT Signal error, actual value, temperature check signal
Flow Control System

Error messages on execution of the function X.TUNE (AUTOTUNE)

Display Cause of error Remedy
X.ERR 1 No compressed air connected Connect compressed air
X.ERR 2 Compressed air failure during Check compressed air supply
AUTOTUNE
X.ERR 3 Exhaust side of actuator or positioning not possible, device faulty
system leaky
X.ERR 4 Pressurizing side of positioning system not possible, device faulty
leaky
X.ERR 6 The end positions for POS-MIN and Check whether the allocation of the end
POS-MAX lie too close together positions to POS-MIN and POS-MAX via
function TUNE-POS is correct.
If incorrect: repeat execution of TUNE-
POS.
If correct: TUNE-POS with this allocation of
end positions is impossible, they lie too
close together.
X.ERR 7 False allocation of POS-MIN and POS- To determine POS-MIN and POS-MAX,
MAX drive the actuator in each case in the
direction shown on the display.

Error message on execution of the function P.Q'LIN

Display Cause of error Remedy
Q.ERR 1 No pressure supply connected Connect pressure supply
No change in process variable Check process, if applicable, switch on
pump or open shut-off valve
Q.ERR 2 Current curve point of the valve stroke
not reached, since
• supply pressure failure during • Check supply pressure
P.Q ’LIN or
• no AUTOTUNE has been executed • Execute AUTOTUNE

24 - 8750
 INSTALLATION

Error message on execution of the function LEAK MEAS

Display Cause of error
L.ERR 1 No admission pressure at the controller unit
(> 50 mbar).
L.ERR 2 Control does not fully close.
L.ERR 3 • No leakage detectable:
the difference between admission
pressure and conveyance pressure is so
low, even at slight valve opening, that no
air leak can be measured.
• Leakage too great:
while the valve was being opened, the
conveyance pressure did not rise. Hence
no reference points for the characteristic
could be registered.
Remedy
Switch on compressor before start of
leakage measurement.
Execute AUTOTUNE.
• The leakage characteristic must be
deactivated since the precision of air flow
control cannot be raised.
• Make sure that the conveying pipe is
closed and the blocking air is open.

Other malfunctions
Problem
POS = 0 (for CMD > 0 %) or
POS = 100 % (for CMD < 100 %)
PV = 0 (for SP > 0) or
PV = PV⊥ (for SP > SP⊥)
Possible causes Remedy
Tight closure function CUTOFF Deactivate
has been activated inadvertently tight closure function or
or no control air has been connect control air
connected

8750 - 25
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