TOP Control System / ON/OFF and Proportional /-Way, / Advantages/Benefits Decentralized Intelligence for ON/OFF and Proportional control of processes Customized System Solutions for Easy LINK and Easy Networking together with sensors Up to % lower Total Cost of Ownership Design/Function The diaphragm valve system is designed for ON/OFF control and Proportional control process applications with various communication possibilities with sensors and a. The diaphragm valve system consists of three variable modules, the valve body, the pneumatic actuator and the TOP Control. ON/OFF control version: ON/OFF control of a diaphragm valve Integrated pilots for single acting or double acting versions Integrated mechanical or inductive limit switches Position feedback Modular electrical interfaces ASI Bus communications Proportional control version: Position control or process control with an integrated PID controller Internal or external setpoint Autotune function Programmable flow curves Sensor input signals (4 ma, Frequency, Pt ) Binary inputs and outputs Modular electrical interfaces Analog position output Up to limit switches with position feedback PROFIBUS DP and DeviceNet communication Applications Body Materials Plastic: Contaminated, aggressive fluids up to 4 F Cold formed stainless steel: Polluted, dirty, abrasive, highly viscous liquids up to 4 F Forged stainless steel: Ultra-pure, sterile, aggressive, abrasive, highly viscous liquids up to 4 F Industries Water treatment Pharmaceutical industry Bio-technology Cosmetic industry Chemical processing Food and feed industry Textile dyeing and bleaching Medical technology Pulp and paper industry Machine industry Burkert Contromatic USA 6 McGaw Avenue Irvine, CA 964 Tel. 949.. Fax 949..9 www.burkert-usa.com Burkert Contromatic Inc. 76 Pacific Road, Unit Oakville, Ontario, Canada L6L 6M5 Tel. 95.47.5566 Fax 95.47.96 Fluid Control Systems
Fluid A Variety Control of System Optional with Diaphragm Modules Valve to Choose from Sizes: Materials: ø6. mm PA with Stainless Steel ø. mm thread connections ø. mm PPS with Stainless Steel ø. mm thread connections Circuit Functions: Single acting - normally closed by spring return - normally open by spring return (ON/OFF control only) Double acting Power supply (-wire technology): 4 VDC 4 V -wire standard signal 4 V -wire bus Valve Bodies Diaphragm Materials: PTFE and FKM CSM Valve Sizes [inch (mm)]: ø/ () ø-/4 () ø/4 () ø () ø () ø () Valve Materials and Corresponding Connections: Plastic - PVC with true union or solvent spigot - PP with fusion spigot - PVDF with fusion spigot Cold formed stainless steel - Threaded ends: G, NPT and Rc - Butt weld ends: ISO 4, DIN R, O.D. tubing (BS 4 Part ) - Flange: DIN 6, ANSI Class, JIS K Forged stainless steel - Butt weld ends: ISO, DIN series, SMS, BS O.D. tubing, JIS sanitary, JIS utility - Clamp connection: ISO 5, BS 4 (Tri-Clamp ) - Dairy union: DIN 5 Power supply: 4 VDC 4 V -wire bus V/6 Hz V/6 Hz
TOP Control System / TOP Control Pneumatic connection: G /4 /4 NPT Rc /4 Proportional as Position Controller Process Controller Integrated pilot valve: x /-way (single acting) 4 x /-way (double acting) Limit switches (, or ): Inductive Signal Inputs and Outputs Inputs: Frequency Pt 4 ma Setpoint 4 ma V 5 V ma Binary Outputs: Binary position feedback x binary Analog position feedback Electrical Interfaces PG cable glands EaseOn box Multipin Field Bus PROFIBUS/ DeviceNet Proportional Control ON/OFF Control Control Head ON / OFF Signal Outputs Electrical Interfaces Pneumatic connection G /4 /4 NPT Rc /4 Integrated pilot valve: /-way (single acting) 5/-way (double acting) Position feedback ASI-bus PG cable glands EaseOn box Multipin (ASI-bus) Cable end with ASI-clip Limit switches (, or ): Mechanical Inductive
ON/OFF Control Fluid Control System with Diaphragm Valve Configuration Electrical Interfaces Integrated Pilot Valve Functions: Single acting (NC or NO by spring return): /-way Double acting: 5/-way Power consumption: < W Multipin M ASI plug (4 pins) PG Cable gland Blind plate Communication Line Power supply: 4 VDC ±% (no technical direct voltage) Residual ripple % V/6 Hz V/6 Hz Round cable with ASI clip Blind plate Command Line On/Off PG cable glands (wiring on terminal strip) Command line (Power supply) Limit switches Pneumatic Connections Supply port: Service port: Exhaust port: G /4 G / G /4 /4 NPT (pre-mounted) /4 NPT Rc /4 Rc /4 Pneumatic Data Medium: Instrument air (filtered, non-lubricated) Pressure range: 45 to PSI C v :. Operation Data Rating: NEMA 4 Ambient temp.: F to F EaseOn box (wiring by push-in and turn-off) Command line Power supply Limit switches Outputs 4
TOP Control System / Communication ASI Bus Wiring: -wire ASI-cable for ON/OFF command, position feedback and power supply V with ASI-interface ASI Topology of Network Line Tree Star Ring Easy LINK Sensor switch or relay output Easy LINK with Sensor (Control) Flow Control (dosing / batching / filling) Analytical Control (dosing) Easy Networking Pressure Control (stabilizing pressure range) Level Control (filling / stabilizing / discharging & overfill protection) Temperature Control (stabilizing temperature range) for details, please see corresponding datasheets Position Feedback, or Limit switch(es): Inductive (4 VDC) - Upper / Lower (NO), binary output /4 V Mechanical (4 VDC, 5 A) - Upper / Lower (NO), /4 V - Upper / Lower (NC), 4/ V ( and V/6 Hz, 5 A) - Upper / Lower (NO), / or V - Upper / Lower (NC), or / V Upper position and / or Lower position Counter Acoustic alarm Visual alarm 7 6 5
Proportional Control Fluid Control System with Diaphragm Valve Configuration Electrical Interfaces Intelligent Positioner Process controller - integrated PID Integrated Pilot Valve DeviceNet (Multipin) (*: Pins) DeviceNet M6 plug (4*) Power supply (plug not necessary when power supplied by bus) M plug (4*) Communication Line Functions: Single acting (NC by spring return): x /-way + exhaust valve (optional) Double acting: 4 x /-way Power consumption: < 5 W Power supply: 4 VDC ±% (no technical direct voltage) Residual ripple % Sensor input incl. Sensor supply (actual process value) M plug (4*) PROFIBUS DP (Multipin) (*: Pins) PROFIBUS DP Rect. plug (9*) Sensor input incl. Sensor supply (actual process value) M plug (4*) Outputs: Limit switches M socket (4*) Power supply M plug (4*) Outputs: Limit switches M socket (4*) Inputs Display at the back PG Cable Glands (wiring on terminal strip) Power supply External setpoint Analog position feedback Actual process value Sensor input incl. Sensor supply or alternatively Binary outputs (selection by jumper) EaseOn Box (wiring by push-in and turn-off) Power supply Pneumatic Connections Supply port: Service port: Exhaust port: G /4 G / G /4 /4 NPT (pre-mounted) /4 NPT Rc /4 Rc /4 Pneumatic Data Medium: Instrument air (filtered, non-lubricated) Pressure range: 45 to PSI C v :. External setpoint Analog position feedback Multipin (*: Pins) Signals to : Analog position feedback Binary outputs Binary input External setpoint M6 plug (*) Actual process value Sensor input incl. Sensor supply or alternatively Binary outputs (selection by jumper) Power supply M plug (4*) Outputs Operation Data Rating: NEMA 4 Ambient temp.: F to F Sensor input incl. Sensor supply (actual process value) M plug (4*) Outputs: Limit switches M socket (4*) 6
TOP Control System / Communication Inputs Input Easy Link with Sensor (Control) Outputs Binary 4 V / V: PG / EaseOn version: instead of input actual process value Communication Line DeviceNet PROFIBUS DP Actual process value: Sensor Visual alarm with Bus interface Acoustic alarm Flow Control (dosing / batching / filling) Analytical Control (dosing) Pressure Control (stabilizing pressure range) Level Control (filling / stabilizing / discharging & overfill protection) Temperature Control (stabilizing temperature range) for details, please see corresponding data sheets Input External setpoint: - 4 - ma - - ma - - V - - 5 V Input (Binary) - V / - V: Switch (sensor or mechanical) Easy LINK Actual process value: Sensor (only for versions with integrated PID) Easy LINK with Sensor (Control) Flow Control (dosing / batching / filling) Analytical Control (dosing) Pressure Control (stabilizing pressure range) Level Control (filling / stabilizing / discharging & overfill protection) Temperature Control (stabilizing temperature range) for details, please see corresponding data sheets Outputs Position feedback limit switch(es): Inductive - Upper / Lower (NC), 4 V / V Display Visual alarm Acoustic alarm Outputs Binary 4 V / V: PG / EaseOn version: instead of input actual process value (sensors) Visual alarm Acoustic alarm Output Analog position feedback: Display 7
TOP Control System / Proportional Functional Diagram / Materials 6 5 4 External process setpoint External position setpoint Process Controller Actual position Position transducer Position Controller Actual process value Positioner:. Supply valve. Exhaust valve Supply Exhaust The TOP Control as position controller has standard signal inputs to preset the external position set points. An integrated microprocessor compares the actual position with the external set point and adjusts the valve to the desired position by activating the internal pilot valves. Position feedback, binary outputs and limit switch outputs can be connected to a central. The TOP Control as process controller uses an external process signal (i.e. coming from a sensor as frequency, Pt or 4- ma) to adjust the position of the valve to the desired process setpoint, preset by an external or fed into the TOP Control manually. The process control as a main control circuit dominates with a PID algorithm the position control circuit in a cascade function. Materials: Sensor Valve Body Plastic - PVC with true union or solvent spigot - PVDF with fusion spigot Cold formed stainless steel - G, NPT and Rc threaded - Butt weld ends ISO 4, DIN R, O.D. tubing (BS 4 Part ) - Flange DIN 6, ANSI Class, JIS K Forged stainless steel - Butt weld ends ISO, DIN series, SMS, BS O.D. tubing, JIS sanitary, JIS utility - Clamp connection ISO 5, BS 4 (Tri-Clamp ) - Dairy union per DIN 5 Diaphragm PTFE and FKM CSM PA (Poly Amide) or PPS (Poly Phenylene Sulfide) 4 5 6 TOP Control (lower cap - black) POM (Poly Oxy Methylene) TOP Control (sealing) NBR (Nitryl Buna Rubber) TOP Control (upper cap - transparent) PSU (Ultrason S)
TOP Control System / TOP Control as Position Controller Disturbance Position setpoint value + Position setpoint value Supply Exhaust Position system solenoid valves Control valve Valve output Position transducer Position control loop The actual position of the pneumatic actuator is sensed by a position transducer. The position controller compares this actual value with an internal or external setpoint value. In case of a control difference, a pulse width modulated voltage signal transmits the new position value to the position system. TOP Control as Process Controller Disturbance Process setpoint value + Process controller Position control loop Valve output Process Process parameter Transmitter When the TOP Control is used for process control, the position control loop works as a secondary service control loop. The process controller in the main control loop has a PID algorithmic function. The process setpoint value will be compared with the actual value of the process parameter to be controlled. This actual value is a sensor signal. 9
TOP Control System / Proportional Software Characteristics Specific Functions of the Positioner: Autotune Function Automatic adjustment to the connected valve (self calibration). 5 s Characteristic Curves for Process Valve Adjustment (correction characteristics) - linear curve - equal percentage curve; rangeability : - equal percentage curve; rangeability : - equal percentage curve; rangeability : - inverse equal percentage curve; rangeability : - inverse equal percentage curve; rangeability : - inverse equal percentage curve; rangeability : - freely programmable curve; user defined ( points) Different Inputs 4 ma, ma, V or 5 V Split Range of the Set Value Signal Range The signal is split in two or more positions. This allows the standard signal to split into two or more ranges (with or without overlap), which are transferred to two or more positioners. This again enables you to use two or more valves partially either simultaneously or in sequence as a final controlling element. % : : % Linear : : % % % plug travel Pos. Pos. % Dead Band The positioner acts only if a specified control difference is measured. Inversion of the Effective Direction of Actual Value and External Setpoint Closed Tight Function The valve is tightly closed over the tightness process range. Stroke Limitation Speed Limitation To open or close the valve with a defined maximum speed. Safety Position / Code Lock The valve moves to a specified safety position. standard signal Additional Specific Functions of the Positioner with Integrated PID: Control Type: PID Autotune Function Self adaptation of the process controller to the actual process conditions. Teach In (for Flow Control Systems) Calibration of Parameters Proportional coefficient, reset time, action rate and operating point. Input Signals to be Scaled Analog input 4 ma, frequency or Pt Internal (via display keys) or External Setpoint
TOP Control System Plastic Technical Data Circuit Functions A /-way valve normally closed by spring return Specifications Flow Capacity Plastic A P B /-way valve normally open by spring return I /-way valve with double-acting actuator Valve Size C v Control Pressure for Max. Operating Pressure for Seal Weight ( Orifice) On/Off Continuous C ircuit Function Circuit Function (A, B and I) S ize ø ( Diaphragm) PVC, True Union Control Control A PVC, True Unio n PVC, Solvent Spigot PVC, Solvent Spigot PVDF, Fusion Spigot PVDF, Fusion Spigot On/Off Continuous N PT [ mm] [PSI] [ psi] [[PSI] psi] [ mm] [ lbs. ] [lbs.] / 4. 6-7 6 6.7 6.6 / 4. 6-7 6 PTFE/ 6.7 6.6 /4. - 7 7.9.7 /4. - 7 PTFE/ 7.9.7 4. 6 Please See - 7..59 4. 6 Separate - 7 PTFE/..59 -/4. Chart 5-7.46.9 -/4. Below 5-7 6 PTFE/.46.9. 67-7.7 6.. 67-7 PTFE/.7 6. 46. 5-7.5.96 46. 5-7 PTFE/.5.96 All pressures quoted are gauge pressures with respect to the prevailing atmospheric pressure. ) Control pressures circuit functions B and I, please see control pressure charts on next page. Plug Travel [%] / (DN ) /4 (DN ) (DN ) -/4 (DN ) -/ (DN ) (DN )...46.7..5.7.7..4 6.55.5..9.45 5.96..7.5.7 4..6..4.77.4 7. 6.4.9.95 6.9 4... 4.6 49.4 7. 5.6.9 4.57 9.9 57..5 6.7.79.74 4.5 64.5 9.5.9 6.6 6.9 4.5 67.6 4.44.54 6.96 7. 4.9 7. C v B P A P Operating Data Connections PVC, true union PVC, solvent spigot PVDF, fusion spigot Circuit function A, B and I Nominal pressure PSI Min. control pressure 9 PSI Max. control pressure 9 PSI Max. viscosity 6 centistokes Ambient temperature min. F ( C) max. F ( C) Fluid temperature with PVC min. F ( C) max. F (6 C) with PVDF min. F ( C) max. 4 F ( C) with PP min. 4 F (- C) max. 4 F ( C) Body material PVC, PVDF or PP Seal material or /PTFE Fluids Contaminated / Aggressive Operating pressure depending on fluid temperature DN /" - - " (DN -) 9 7 6 5 4 Operating Pressure (bar) Note: bar = 4.5 PSI PVC PP PVDF 6 Temperature (ºC)
TOP Control System Plastic Control Pressures Circuit Function B and I size ø6 mm Circuit Function B and I size ø mm Fluid Pressure [bar] 9 7 6 5 4 Note: bar = 4.5 PSI -seal DN /" /" PTFE-seal 4 5 6 Control Pressure [bar] DN Fluid Pressure [bar] 9 7 6 5 4 Note: bar = 4.5 PSI -seal PTFE-seal DN DN /4" /4" -seal PTFE-seal DN " 4 5 6 Control Pressure [bar] DN " Circuit Function B and I size ø mm Circuit Function B and I size ø mm Fluid Pressure [bar] 9 7 6 5 4 Note: bar = 4.5 PSI -seal -/4" DN PTFE-seal 4 5 6 Control Pressure [bar] -/4" DN Fluid Pressure [bar] 9 7 6 5 4 Note: bar = 4.5 PSI -seal -seal -/" DN PTFE-seal PTFE-seal -/" " DN DN 4 5 6 Control Pressure [bar] DN "
TOP Control System Plastic Dimensions [inch] PVC with True Union Orifice Measurements Size ø A B C D E F G N PT [ mm] [ mm] [inch] / 6 5..7.4..6.69 /4 5.9.9..6.96. 6.5..45.6.96.6 -/4 7.55.57.6.7 4.9.9.74.96.4. 6..6.47.4.7. 6. 4.5 max. ø 9 E D F G 6. C B A Dimensions [inch] PVC with Solvent Spigot PP with Fusion Spigot PVDF with Fusion Spigot Orifice Measurements Size ø A B C D E F G N PT [ mm] [ mm] [inch] / 6 4..7 9.96.4..6.55 /4 5.66.9..6.96.7 6.6..45.6.96. -/4 6.5.57.5.7 4.9. 7.6.96.9. 6....4 6.6. 6..5 max. ø 9 6. G C E D F B DN A
TOP Control System Cold Formed Stainless Steel Technical Data Circuit Functions A /-way valve normally closed by spring return A P B /-way valve normally open by spring return I /-way valve with double-acting actuator B P A Specifications for Threaded Ends, Butt Weld* Ends (*ISO 4 only) and Flange Valve Size C v Control Maximum Seal Weight ( Orifice) On/Off Continuous Pressure Operating Pressure S ize ø ( Diaphragm) Threaded Ends Flange Control C ontrol ( A, B and I) for Circuit Function Butt Weld Ends ( A, B and I) ISO 4 On/Off Continuous On/Off Continuous N PT [ mm] [PSI] [ psi] [PSI][ psi] [ mm] [ lbs. ] [ lbs. ] [ lbs. ] [lbs.] / 6. 6 6.74 4. 6.56 7. / 6. 6 6 PTFE/.74 4. 6.56 7. /4. 5.7 5.5 9. 9. /4. PTFE/ 5.7 5.5 9. 9.. 7 Please See 6.7 6.6.5.. 7 Separate 6 PTFE/ 6.7 6.6.5. -/4. 6 Chart on 5 9.7.4 6. 6.75 -/4. 6 Next Page 5 6 PTFE/ 9.7.4 6. 6.75. 6.7 6..9.6. 6 PTFE/.7 6..9.6 6. 6 6 6.97 7.4 7. 7.55 6. 6 PTFE/ 6.97 7.4 7. 7.55 P Specifications for Butt Weld* Ends (*DIN R only) Valve Size C v Control Maximum Seal Weight ( Orifice) On/Off Continuous Pressure Operating Pressure S ize ø ( Diaphragm) Butt Weld Ends DIN R Control C ontrol ( A, B and I) for Circuit Function ( A, B and I) On/Off Continuous N PT [ mm] [PSI][ psi] [PSI][ psi] [ mm] [ lbs. ] [lbs.] / 5. 6 6.5.96 / 5. 6 6 PTFE/.5.96 /4 5. 6.5.96 /4 5. 6 PTFE/.5.96. Please See 5.9 5.7. Separate PTFE/ 5.9 5.7 -/4. Chart on 5 6.7 6.6 -/4. Next Page 5 PTFE/ 6.7 6.6. 7 6 9.7.4. 7 6 PTFE/ 9.7.4 4. 6.9 6.5 4. PTFE/ 6.9 6.5 Specifications for Butt Weld* Ends (*O.D. Tubing BS 4 Part only) Valve Size C v Control Maximum Seal Weight ( Orifice) On/Off Continuous Pressure Operating Pressure S ize ø ( Diaphragm) Butt Weld Ends Control C ontrol ( A, B and I) f or Circuit Function O.D. Tubing (BS 4 Part ) ( A, B and I) On/Off Continuous N PT [ mm] [PSI][ psi] [PSI] psi] [ mm] [ lbs. ] [lbs.] /4 5. 6.5.96 /4 5. 6 PTFE/.5.96 4. Please See 5.9 5.7 4. Separate PTFE/ 5.9 5.7. 6 Chart on 6 9.7.4. 6 Next Page 6 PTFE/ 9.7.4 49. 6.9 6.5 49. PTFE/ 6.9 6.5 All pressures quoted are gauge pressures with respect to the prevailing atmospheric pressure. 4
TOP Control System Cold Formed Stainless Steel Technical Data Flow Capacity for threaded ends, butt weld* ends (*ISO 4 only) and flange Plug Travel C v [%] / /4 -/4.5.9..46.7.75....7.6 6..5.45.9 4.9. 9.. 5. 6..9.9.4. 7..6.44.4 5. 6.7 9.47 4.74.7.5 49.95 7 4.44..6 6. 4.6 6. 5.49 4..99.99 47.7 79.9 9 6..67. 7.44 49.95 5.7 6..79.74.6[PSI]. 6.5 Flow Capacity for butt weld* ends (*DIN R only) Plug Travel C v [%] / /4 -/4.4.4.9..5.6.9.9...9..49.49.45.7. 7.4.7.7 5. 6.7 7.64.6.75.75 7. 9.5.46.4 6.7.7 9.47.6.7 6.7 7.7.7..76 9.45 5. 4.5 4.5 4..7 4.49 4.7 9 5.6 5.6.67 [PSI].9 7. 4.9 5.6 5.6.79.6.66 4.9 Flow Capacity for butt weld* ends (*O.D. tubing BS 4 Part only) Plug Travel C v [%] /4.4..9.69.9.7.7.54.49..59..7 4.46 7.75.5.75 6.4.4.9 6.7.4. 9. 7.7..54. 4.5.5 6.99 46.6 9 5.6.9. 4. 5.6 4.4.59 49.4 Operating Data Connections Threaded ends G, NPT and Rc Butt weld ends ISO 4 DIN R O.D. tubing (BS 4 Part ) Flange DIN 6 ANSI Class JIS K Circuit function A, B and I Body material Cold formed stainless steel Seal material or /PTFE Fluids Polluted, dirty, abrasive or highly viscous liquids Nominal pressure Min. control pressure Max. control pressure Max. viscosity Ambient temperature Fluid temperature PSI 9 PSI PSI 6 centistokes min. F ( C) max. F ( C) min. 4 F (- C) max. 4 F ( C) Dimensions [inch] Stainless steel - G - NPT - Rc Orifice Measurements Size ø A B C D E F G N PT [ mm] [ mm] [inch] / 6 4. /.4.6..6 /4 4.64 / 4.7.6.96. 5..49.6.96.6 -/4 5.74 -/ 4.5.7 4.9.96 6. -/.. 6..6 7.5.47. 6..75 max. 4.9 max. ø 9 F 4.96 SW C 6. D E DN PN6.44 B A
TOP Control System Cold Formed Stainless Steel Dimensions [inch] Stainless Steel - Butt weld ends per ISO 4 - Butt weld ends per DIN R - Butt weld ends O.D. tubing (BS 4 Part ) max. 4.9 Orifice Measurements per ISO 4 Size ø A B C D E F G N PT [ mm] [ mm] [inch] / 6 4...6.4..6 /4 4.6.5.7.6.6.96 5.7..49.7.6.96 -/4 5..66.5.7.7 4.9 6..9..7. 6. 7.55.7.47.7. 6. max. ø 9 F 6. 4.96 / /4 -/4 6 6 7 5 Measurements per DIN R 4..74.5.4..6 4.6.9.7.5.4..6 5..4.49.5.6.96 5..7.6.5.6.96 6..6.7.5.7 4.9 7.5..47.5. 6. C E G DN PN6.44 /4 -/4 6 Measurements per O.D. Tubing 4..75 9.96.5.4..6 4.4...6.6.96 5.5...6.7 4.9 6...5.6. 6. A D B Dimensions [inch] Stainless Steel - Flange per DIN 6 - Flange per ANSI Class - Flange per JIS K Orifice N PT [mm] Measurements per DIN 6 Size ø [mm] /" /4" " -/4" -/" " A [inch]..9.... B [inch].7..5.5.9.9 C [inch]...4.5 5. 5. D [inch]...... E [inch]..5.5.5.5.5 F [inch]..9.9 4.9 6. 6. 6 5 4 4 6 5 4 7 6 9 6 6 9 4 9 6 9 6 7 5 7 9 7 7 5 9 7 7 5 9 max max.. ø 4.9 9 F 6. C 4.96 /" 6 Measurements per ANSI Class 5..74.4.6. D E /4" 5.9 4..7.6.96 " 6.9 4.5.49.6.96 -/4" 7. 5.5.5.7 4.9 -/" 7.7 5.9.. 6. DN PN6.44 Measurements per JIS K B /" 6 5..74.4.6. /4" 5.9 4..7.6.96 -/4" 7. 5.5.5.7 4.9 -/" 7.7 5.9.. 6. A 6
TOP Control System Forged Stainless Steel Technical Data Circuit Functions A /-way valve normally closed by spring return A P B /-way valve normally open by spring return I /-way valve with double-acting actuator B P A Specifications Valve Size C v Control Pressure Maximum Seal Weight ( Orifice) On/Off Continuous for Circuit Function Operating Pressure S ize ø (Diaphragm) Control C ontrol ( A, B and I) for Circuit Function ( A, B and I) On/Off Continuous N PT [ mm] [PSI] [ psi] [PSI] [ psi] [ mm] [ lbs. ] [lbs.] / 5. 6 6 6 ) E lastomere 4. 4. 4 / 5. 6 6 6 PTFE 4. 4. 4 /4. ) E lastomere 6. 6. 6 /4. Please See PTFE 6. 6. 6. Separate ) E lastomere 6. 5 7.. Chart 6 PTFE 6. 5 7.. 7 Below ) E lastomere 4. 5.. 7 PTFE 4. 5. 6. 4 ) E lastomere. 5. 9 6. PTFE. 5. 9 All pressures quoted are gauge pressures with respect to the prevailing atmospheric pressure. ) Elastomere:, FKM, CSM P Flow Capacity Forged Stainless Steel Plug Travel C v [%] / /4.5...7.7..46..6 6..5..9....69 6. 6.6.4..74.6.5 5. 6.7 5...5 45.6 7 4.44 6.9.9 7.55 5.6 5. 7. 4.5.6 56.6 9 5.7.7.9 4 6.6 5.5.9..7 6.4 Operating Data Connections Butt weld ends ISO 4 DIN R SMS O.D. tubing (BS 4 Part ) JIS sanitary JIS utility Clamp connections ISO 5 BS 4 (Tri-Clamp ) Dairy union DIN 5 Circuit function A, B and I Nominal pressure PSI Control pressure Min. 9 PSI / Max. PSI Maximum viscosity 6 centistokes Ambient temperature F to F ( C to C) Fluid temperature 4 F to 66 F (- C to + C) (Short time temp.) Max. F ( C) (CIP) Body material Stainless Steel (6L) Seal material, FKM, CSM or PTFE Fluids Ultra-pure, sterile, aggressive, abrasive or highly viscous fluids Operating pressure depends on fluid temperature Please see diaphragm selection 7
TOP Control System Forged Stainless Steel Sizes of Assembled TOP Control and Unit [inch] ø ø ø 4. ø 4. ø 4. ø 4. ø ø 4. 67.5 9.59.5.6.6 4. 46. 79.6.6 6.6..96 4.9 7.6 6. Size: ø6 mm Size: ø mm Size: ø mm Size: ø mm
TOP Control System Forged Stainless Steel Valve Body Material Forged Bodies Burkert high quality valve bodies are forged of 6L stainless steel, with Ferrite <.5%, C.% to satisfy the requirements of high purity applications. Defect free surface High quality surface of finished product - free from pinholes, crevices, impurities and subsurface porosity. Imperfections, well accepted in many industrial applications, could present enormous problems as bacteria traps in cell culture or other critical systems. Low ferrite content Relatively ferrite-free alloy eliminates concern regarding ferrite contamination of the process. Surface Finishes Burkert valve bodies meet and exceed the increasingly rigorous industry requirements for surface finishes. The exterior of Burkert valve bodies are glass beaded to a smooth patina, while a choice of two grit specifications is offered for interior surface finish, plus an electropolishing option. Surface finish can be described by using the roughness average (Ra) parameter. Ra is defined as the average value of all absolute distances of the roughness profile from the center line within the measuring length. Electropolishing - A process that combines an electrical current and a chemical bath that removes metal from polished forgings at various rates. This process creates a superior surface finish over that produced by mechanical polishing. The results are more desirable in the critical services found in pharmaceutical and bioprocessing industries. Inherent benefits of electropolishing are: Contaminants such as lubricants and grit particles are removed with the surface layer Improves quality control by exposing surface pits and defective welding Surface leveling or balancing reduces the total surface height by up to % and alleviates much of the surface tension created by mechanical polishing Surface corrosion resistance is improved with the deposition of a continuous layer of chromium enhanced oxide High luster improves overall appearance All surfaces are easier to clean and sterilize Burkert s forged bodies are available with a wide variety of custom surface finishes as low as Ra. Standard combinations of internal and external surface finishes are: Internal Ra ~ to μ in. Satin finish ( grit) External Ra ~ 6μ in. Glass Beaded Internal Ra ~ to μ in. Electro-polish ( grit) External Ra ~ μ in. Electro-polish 9
TOP Control System Forged Stainless Steel Diaphragms Specifically developed to handle the unique challenges of hygienic and sterile applications, Burkert diaphragms are manufactured with exacting material formulation and physical tolerances. They are available in a range of materials which have been proven in the food, biotechnology, pharmaceutical and cosmetic industries. Diaphragms are tested during development and manufacturing to ensure reliability in processing application environments. Diaphragm Materials Material PTFE FKM CSM (Ethylene-Propylene-Dien Monomer) & Color Temperature Range Standards black - F to 4 F FDA and -A white/black + 4 F to 66 F FDA and -A black + F to F FDA and -A black - F to 66 F FDA and -A 75 Pressure vs. Temperature (Diaphragms) Pressure ~ PSI 75 CSM, PTFE/ FKM - 6 6 Temperature ~ F
TOP Control System Forged Stainless Steel End Types Butt Weld Example: DN ( inch) ISO DIN Series SMS O.D. Tubing s s ø d L ød=.7 s=. ød=9. s=.5 ød=. s=. ød=.4 s=.6 ød Standard Configuration Dimensions [inch] Optional Tubing Dimensions [mm] ) Valve O.D. Tubing ISO D IN Series SMS JIS Sanitary JIS Utility L DN L Size ød s ød s ød s ød s ød s ød s /4.54... 9.. 5. 6.. / 4....... 6 9.. 5. 7. /4 4.69. 75.. 9. 6. 9. 6.. 5 7.. 5.... 9.. 7. 9.. 5... 4. 4.. -/ 6.4... 6. 4.. 4.. 5.... 4. 6. 7.56... 9. 6.. 5.. 5 5.... 5 6. 5. ) DIN Series and also available Tri-Clamp d d d L Standard Configuration Dimensions [inch] Optional Configuration Dimensions [mm] Valve ISO 5, SMS 7 L d d d DN L Size d d d /.. 7. 7... 9. 5 9. 7. /4 4.. 6. 7.. 9.. 9 9. 7. 4.. 7.7.. 9.. 4. 5. 5 -/ 5.5.7.7.. 6. 4. 9 4. 5. 5 6..7... 9. 47. 6 56. 5 64. On request; Clamp DIN 676 Sterile Threaded Ends Standard Configuration Dimensions [inch] Optional Configuration Dimensions [mm] Threaded Ends with Beveled Valve DIN 5 Seat, -A-6 Class G Size L G DN L port size G /. 9.. Rd 4 x /" /4...7 Rd 44 x /6" 5..46.. 9.7 Rd 5 x /6" -/ 6.6.99.. 44. Rd x /6" 7..5. 9. 56. Rd 7 x /6" On request; All commonly used dairy unions per RJT, IDF, etc. All valve bodies from Burkert are machined from forged material.
TOP Control System / Fax Order Form: Individual System Configurations Part of Please select modules according specific application (either ON/OFF or Proportional Control): General Data Configuration number: Quantity: Medium Data Medium: Temperature: Pressure: Min. / Max. ON/OFF Control General Data Command line coming from: Sensor Relay/Switch Circuit function: Single acting NC NO (on request) Double acting Material: PA PPS Control Head No Bus or with Bus Communication: ASI Bus Power supply: 4 VDC VDC VDC Electrical connection: PG cable glands PG cable glands (with round cable end) EaseOn box Multipin Limit switches: Mechanical Inductive (for 4 VDC version only) Pneumatic connection: Brass Brass Stainless Steel Stainless Steel G G NPT NPT Rc Rc Proportional Control Circuit function: Single acting (NC) Single acting (NO) Quick exhaust Double acting Material: PA PPS TOP Control No Bus or with Bus Type of control: Position control Process control Communication: DeviceNet PROFIBUS DP Electrical connection: PG cable glands EaseOn box Multipin Outputs: Limit switches (Multipin version only) Analog position feedback Binary outputs (PG cable glands and Ease-On box versions: instead of input actual process value) Inputs: Binary input (Multipin version only) Actual process value instead of binary outputs Pneumatic connection: Brass Stainless Steel G NPT Rc Brass Stainless Steel G NPT Rc Please continue on next page
TOP Control System / Fax Order Form: Individual System Configurations Part of Please select modules according specific application: Valve Body Type Type Item No.: (reference)... Material and corresponding ends: PVC PVDF PP Diaphragm material: PTFE / Butyl PTFE / FKM FKM Orifice: / DN /4 -/4 Ends: True union Fusion spigots Weld ends Solvent spigots Valve Body Type (General Purpose Version) Type Item No.: (reference)... Material and corresponding ends: Formed S.S. Ends: threaded G NPT Rc butt weld ISO 4 DIN R O.D. tubing (BS 4 Part ) flange DIN 6 ANSI Class JIS K Diaphragm material: PTFE / Orifice: / DN /4 -/4 Valve Body Type (High Purity Version) Type Item No.: (reference)... Material and corresponding ends: Forged S.S. Surface finish: External 6μ in (electropolished) μ in Internal -μ in (electropolished) -μ in Diaphragm material: PTFE / FKM CSM Silicon Others... Orifice: / DN /4 Ends: threaded sterile threaded butt weld G NPT Rc DIN 5 ISO DIN - Series Series Series SMS BS O.D. Tubing JIS sanitary JIS utility clamp connect. ISO 5 / SMS 7 BS 4 Tri-Clamp DIN 676 others...
TOP Control System Fax Order Form Part of Customer Data Name of company: Department: Street / No.: City: State: Zip: Country: Name of contact person: Name: Telephone number: Fax Number: email: Signature: to Order Thank you very much for filling in our fax order form. Please fax parts, and of this order form, using the appropriate fax number listed on the front page of this datasheet. If you have any questions concerning this matter, please do not hesitate to contact us. Fluid Control Systems In case of special requirements please consult for advice. We reserve the right to make technical changes without notice. 6/_US-en 4