PMA Proze- und Maschinen-Automation GmbH

Industrial controller KS 40-1, KS41-1 and KS42-1

KS40-1 KS41-1 KS42-1

KS40-1 KS41-1

KS42-1 Operating manual

English 9499-040-62711
Valid from: 8473

 BlueControl
More efficiency in engineering, more overview in operating: The projecting environment for the BluePort controllers

rs .pm PMA e i V ww on n M i w or

! es on ON dat e TI Up e.d ENand nlin D TTion a-o -C A

Description of symbols:

g General information a General warning l Attention: ESD sensitive devices

PMA Proze- und Maschinen-Automation GmbH Printed in Germany All rights reserved. No part of this document may bereproduced or published in any form or by any means without prior written permission from the copyright owner. A publication of PMA Proze- und Maschinen Automation P.O.Box 310229 D-34058 Kassel Germany

Contents

1 2 2.1 2.2 3 3.1 3.2 3.3 3.4 3.5

3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . 6 Connecting diagram. . . . . . . . . . . . . . . . . . . . . . . . . 6 Terminal connection . . . . . . . . . . . . . . . . . . . . . . . . 6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Behaviour after power-on . . . . . . . . . . . . . . . . . . . . . 11 Operating level . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Maintenance manager / Error list . . . . . . . . . . . . . . . . 12 Self-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preparation for self-tuning. . . . . . . . . . . . . . . . . . . . . . . Self-tuning sequence . . . . . . . . . . . . . . . . . . . . . . . . . Self-tuning start . . . . . . . . . . . . . . . . . . . . . . . . . Self-tuning cancellation . . . . . . . . . . . . . . . . . . . . . . . Acknowledgement procedures in case of unsuccessful self-tuning Examples for self-tuning attempts . . . . . . . . . . . . . . . . . . . . . . . 14 14 15 15 16 16

3.6 3.7 3.8 4 4.1 4.2 4.3 4.4

4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6 4.4.7

Manual tuning . . . . . Alarm handling . . . . Operating structure . . Configuration level . . Configuration survey Configuration . . . . . Set-point processing . . Configuration examples

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17 18 20 21 21 22 29 30
30 31 32 33 34 35 36

On-Off controller / Signaller (inverse) . . . . . . . . . . . . 2-point controller (inverse) . . . . . . . . . . . . . . . . . . 3-point controller (relay & relay) . . . . . . . . . . . . . . . 3-point stepping controller (relay & relay) . . . . . . . . . . Continuous controller (inverse) . . . . . . . . . . . . . . . . D - Y - Off controller / 2-point controller with pre-contact . KS4x-1 with measured value output . . . . . . . . . . . . .

Operating KS4x-1

5 5.1 5.2 5.3 5.4 5.5

5.5.1 5.5.2

Parameter setting level . Parameter survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parameters . . . . . . . . Input scaling . . . . . . .

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37 37 37 37 38 40

Input Inp.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Input InP.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6 7 8 8.1
8.1.1 8.1.2 8.1.3 8.1.4

Calibration level . Programmer . . Timer . . . . . . . Setting up the timer

Operating modes . Tolerance band . . Timer start . . . . . Signal end . . . . . . . . .

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41 44 46 46
46 47 47 48

8.2 8.3 9 10 11 12 12.1

Determining the timer run-time Starting the timer . . . . . . BlueControl . . . . . . . . . . Versions . . . . . . . . . . . . Technical data . . . . . . . . Safety hints . . . . . . . . . . Resetting to factory setting . .

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48 48 49 50 51 55 56

Operating KS4x-1

Mounting

1 Mounting
min.48 (1.89")
(
(3.62" +0.03)

Front view KS41-1

48 (1.89")
max. 60C 0C
SP.x

(0 1. .0 .1 4. 0 .0 .4 ")

92

10

4 0.

")

11

6 4.

+0,8

")

126.
125

run

min.

Ada

Err

KS 41-1 universal

max. 95% rel.

96 (3.78")

96 (3.78")

SP.X

126
125

run

Ada

45

+0,6

Err

(1.77" +0.02)

Front view KS42-1

SP.x

KS 40-1 universal

96 (3.78")

run
Ada

Err

48 (1.89")

126.
125
96 (3.78")

Loc

10V i mA/Pt

Pt Loc Loc 10V mA/ 10V mA/Pt

Loc 10V mA/Pt

KS 42-1 universal

Safety switch

or:

*
Safety switch: For access to the safety switches, the controller must be withdrawn from the housing. Squeeze the top and bottom of the front bezel between thumb and forefinger and pull the controller firmly from the housing..
10V i mA/Pt Loc right left open closed
1 1

Current signal / Pt100 / thermocouple at InP.1 Voltage signal at InP.1 Access to the levels is as adjusted by means of BlueControl (engineering tool) 2 all levels accessible wihout restriction
2

Factory setting

Default setting: display of all levels suppressed, password PASS = OFF

switch 10V i mA/Pt in position a Safety switch open may lead toalways functions! left or right. Leaving the safety faulty

Caution! The unit contains ESD-sensitive components.

Operating KS4x-1

Electrical connections

2 Electrical connections 2.1 Connecting diagram

Option
1

di2 di3 UT

(2) 3 4 5 6 7 8 9 10

1 2 3 4 5

L N

90...250V 24V AC/DC

OUT1 OUT2

d e c b
Logic

7 8

OUT3

Modbus RTU
RXD-B RGND DATA B DATA A GND RXD-A TXD-B TXD-A

11 12 13 14 15 (16) 17

9 10 11 12 13 14 15

HC mA
mA 0..10 V*

INP2 di1 INP1

RS485

RS422

b c

Safety switch mA i V in position left

Dependent of order, the controller is fitted with : w flat-pin terminals 1 x 6,3mm or 2 x 2,8mm to DIN 46 244 or screw terminals for 0,5 to 2,5mm

2.2 Terminal connection

Power supply connection 1 See chapter 11 "Technical data" Connection of input INP1 2 Input for variable x1 (process value) a thermocouple b resistance thermometer (Pt100/ Pt1000/ KTY/ ...) c current (0/4...20mA) d voltage (0/2...10V)

Connecting diagram

Operating KS4x-1

Electrical connections
Connection of input INP2 3 Heating current input (0...50mA AC) or input for ext. set-point (0/4...20mA) Connection of input di1 4 Digital input, configurable as switch or push-button Connection of outputs OUT1/2 5 Relay outputs 250V/2A normally open with common contact connection Connection of output OUT3 6 a relay (250V/2A), potential-free changeover contact universal output b current (0/4...20mA) c voltage (0/2...10V) d transmitter supply e logic (0..20mA / 0..12V) Connection of inputs di2/3 7 (option) Digital inputs (24VDC external), galvanically isolated, configurable as switch or push-button Connection of output UT 8 (option) Supply voltage connection for external energization Connection of bus interface 9 (option) RS422/485 interface with Modbus RTU protocol
Logic

3 INP2 current tansformer

1 2 3 4 5

6
7 8
SSR _ +

9 10 11 12 13 14 15

5 OUT1/2 heating/cooling
1 2 3 4 5

6
7 8

9 10 11 12 13 14 15

+ N

Operating KS4x-1

Terminal connection

Electrical connections

7 8 di2/3, UT 2-wire transmitter supply

Option
+24VDC 5mA
1
(2)

6 OUT3 transmitter supply

1 2 3 4 5

5mA 0V

4 5 6 7 8 9 10 11

+
17,5V 22mA

13V 22mA

6
7 8

OUT3

9 10 11 12 13 14 15

+
1 3

12 13 14 15
K
(16)

+
+ -

2 3

17

K
1

a If U and the universal output OUT3 is used there may be no external galvanic connection between measuring and output circuits!
T

6 OUT3 as logic output with solid-state relay (series and parallel connection)

Series connection

Parallel connection

3 4 5

Imax=22mA

SSR _ + SSR _

4V
Imax=22mA
SSR _ + SSR _ +

Logic
7 8

7 8

12V

4V
+ SSR _

12V

9 10

4V
+

Terminal connection

Operating KS4x-1

Electrical connections

9 RS485 interface (with RS232-RS485 interface converter) *

12 12

RGND

13 14

10 11 12 13 14 15

RGND

12

13 14

10 11 12 13 14 15

RGND

13 14

10 11 12 13 14 15

RT = 120...200 Ohm
DATA B

15 (16) 17

DATA B

15 (16) 17

DATA B

15 (16)

PC

RT

DATA A

DATA A

DATA A

17

R=100 Ohm

converter RS485-RS232
RGND connection optional

max. 1000m Twisted Pair

RT RT = 120...200 Ohm

Interface description Modbus RTU in seperate manual: see page 50.

KS4x-1 connecting example:

L1 L2

fuse
KS 40-1
1 2 3 4 5

fuse
TB 40-1 1 Temperature limiter
1 2

fuse

contactor

3 4 5

6
Logic

SSR
_ +

6
7 8

7 8

9 10 11 12 13 14 15

9 10 11 12 13 14

reset +

15

heating

N1 N2

1 TB 40-1 Temperature limiter Standard version (3 relays): TB40-100-0000D-000 r other versions on request

a CAUTION:

Using a temperature limiter is recommendable in systems where overtemperature implies a fire hazard or other risks.

Operating KS4x-1

Terminal connection

Operation

3 Operation 3.1 Front view

1 Status of switching outputs OuT.1... 3 2 Lit with limit value 1 ( PArA / Lim ) not exceeded 3 Process value display 4 Set-point, controller output 5 Signals ConF and PArA level 6 Programmer or timer running 7 Self-tuning active 8 Entry in error list 9 Set-point SP.2 or SP.E is effective 0 Set-point gradient effective ! Manual/automatic switch-over: Off: Automatic On: Manual (changing possible) Blinks: Manual (changing not possible (r ConF/ Cntr/ MAn) " Enter key: calls up extended operating level / error list Up/down keys: changing the set-point or the controller output value $ Manual mode /spec. function ( ConF / LOGI ) % PC connection for BlueControl (engineering tool)

KS41-1
SP.x

KS40-1
1 2 3 OK

1 2 3 5 6 7 8 4 "

126.
125

run

Ada

Err

KS 41-1 universal

KS42-1
SP.x

9 0 !

SP.x

126.
125

run

Ada

Err

run
Ada

Err

126.
125
$
%
KS 40-1 universal

KS 42-1 universal

LED colours: LED 1, 2, 3: LED OK: other LEDs: yellow green red

In the upper display line, the process value is always displayed. At parameter, configuration, calibration as well as extended operating level, the bottom display line changes cyclically between parameter name and parameter value.

Front view

10

Operating KS4x-1

Operation

3.2 Behaviour after power-on

After supply voltage switch-on, the unit starts with the operating level. The unit is in the condition which was active before power-off. If KS4x-1 was in manual mode before power-off, the controller starts with correcting value Y2 after switching on again.

3.3 Operating level

The content of the extended operating level is determined by means of BlueControl (engineering tool). Parameters which are used frequently or the display of which is important can be copied to the extended operating level.

Automatic

Manual
i i

126
time out

125

y 21

126

time out

y 21

126
only display

126

time out

125

Extended operating level

Errorliste (if error exists)

FbF.1

126
Err

display switching

126
2
Err

Operating KS4x-1

11

Behaviour after power-on

Operation

3.4 Maintenance manager / Error list

With one or several errors, the extended operating level always starts with the error list. Signalling an actual entry in the error list (alarm, error) is done by the Err LED in the display. To reach the error list press twice.
Err LED status blinks (Status 2) lit (Status 1) off (Status 0) Signification Alarm due to existing error
SP.x

126
125

run

Ada

Err

Proceed as follows - Determine the error type in the error list via the error number - -Change to status 1 after error removal. Error removed, - Acknowledge the alarm in the error list pressing Alarm not acknowledged key or - The alarm entry was deleted (Status 0) . No error, -Not visible except when acknowledging all alarm entries deleted

Error list:
Name Description E.1 Internal error, E.2

Cause - E.g. defective EEPROM

cannot be removed Internal error, can be - e.g. EMC trouble reset

E.4

Hardware error

- Codenumber and hardware are not identical

FbF.1 Sensor break INP1 Sht.1 POL.1 FbF.2 Sht.2 POL.2 HCA

Short circuit INP1 INP1polarity error Sensor break INP2 Short circuit INP2 INP2 polarity Heating current alarm (HCA)

SSr

Sensor defective Faulty cabling Sensor defective Faulty cabling Faulty cabling Sensor defective Faulty cabling Sensor defective Faulty cabling Faulty cabling Heating current circuit interrupted, I< HC.A or I> HC.A (dependent of configuration) - Heater band defective Heating current short - Current flow in heating circuit (SSR) circuit with controller off - SSR defective

Possible remedial action Contact PMA service Return unit to our factory Keep measurement and power supply cables in separate runs Ensure that interference suppression of contactors is provided Contact PMA service Elektronic-/Optioncard must be exchanged Replace INP1 sensor Check INP1 connection Replace INP1 sensor Check INP1 connection Reverse INP1 polarity Replace INP2 sensor Check INP2 connection Replace sensor INP2 Check INP2 connection Reverse INP2 polarity Check heating current circuit If necessary, replace heater band

- Check heating current circuit - If necessary, replace solid-state relay

Maintenance manager / Error list

12

Operating KS4x-1

Operation
Name Description LooP Control loop alarm

(LOOP)

AdA.H Self-tuning heating

alarm (ADAH) AdA.C Self-tuning heating alarm cooling (ADAC) LiM.1 stored limit alarm 1
Lim.2 stored limit alarm 2 Lim.3 stored limit alarm 3 Inf.1 time limit value

Cause - Input signal defective or not connected correctly - Output not connected correctly - See Self-tuning heating error status

Possible remedial action - Check heating or cooling circuit - Check sensor and replace it, if necessary - Check controller and switching device - see Self-tuning heating error status

- See Self-tuning cooling error - see Self-tuning cooling error status status - adjusted limit value 1 exceeded - adjusted limit value 2 exceeded - adjusted limit value 3 exceeded - adjusted number of operating hours reached - adjusted number of duty cycles reached check process check process check process application-specific application-specific

message Inf.2 duty cycle message (digital ouputs)

g g

Saved alarms (Err-LED is lit) can be acknowledged and deleted with the digital input di1/2/3 or the -key. Configuration, see page 27: ConF / LOGI / Err.r If an alarm is still valid that means the cause of the alarm is not removed so far (Err-LED blinks), then other saved alarms can not be acknowledged and deleted. Self-tuning heating ( ADA.H) and cooling ( ADA.C) error status:

Error status 0 3 4 5 6 7 8

Description No error Faulty control action No response of process variable Low reversal point Danger of exceeded set-point (parameter determined) Output step change too small (dy > 5%) Set-point reserve too small

Behaviour Re-configure controller (inverse i direct) The control loop is perhaps not closed: check sensor, connections and process Increase ( ADA.H) max. output limiting Y.Hi or decrease ( ADA.C) min. output limiting Y.Lo If necessary, increase (inverse) or reduce (direct) set-point Increase ( ADA.H) max. output limiting Y.Hi or reduce ( ADA.C) min. output limiting Y.Lo Increase set-point (invers), reduce set-point (direct) or increase set-point range (r PArA / SEtp / SP.LO and SP.Hi )

Operating KS4x-1

13

Maintenance manager / Error list

Operation

3.5 Self-tuning
For determination of optimum process parameters, self-tuning is possible. After starting by the operator, the controller makes an adaptation attempt, whereby the process characteristics are used to calculate the parameters for fast line-out to the set-point without overshoot. The following parameters are optimized when self-tuning: Parameter set 1: Pb1 - Proportional band 1 (heating) in engineering units [e.g. C] ti1 - Integral time 1 (heating) in [s] r only, unless set to OFF td1 - Derivative time 1 (heating) in [s] r only, unless set to OFF t1 - Minimum cycle time 1 (heating) in [s] r only, unless Adt0 was set to no self-tuning during configuration by means of BlueControl . Pb2 ti2 td2 t2 - Proportional band 2 (cooling) in engineering units [e.g. C] - Integral time 2 (cooling) in [s] r only, unless set to OFF - Derivative time 2 (cooling) in [s] r only, unless set to OFF - Minimum cycle time 2 (cooling) in [s] r only, unless Adt0 was set to no self-tuning during configuration by means of BlueControl

3.5.1 Preparation for self-tuning w Adjust the controller measuring range as control range limits. Set values rnG.L and rnG.H to the limits of subsequent control. (Configuration rControllerrlower and upper control range limits) ConFrCntrr rnG.L and rnG.H w Determine which parameter set shall be optimized (see tables above). 3.5.2 Self-tuning sequence The controller outputs 0% correcting variable or Y.Lo and waits, until the process is at rest (see start-conditions on page 8). Subsequently, a correcting variable step change to 100% is output. The controller attempts to calculate the optimum control parameters from the process response. If this is done successfully, the optimized parameters are taken over and used for line-out to the set-point. With a 3-point controller, this is followed by cooling. After completing the 1st step as described, a correcting variable of -100% (100% cooling energy) is output from the set-point. After successfull determination of the cooling parameters, line-out to the set-point is using the optimized parameters.

Self-tuning

14

Operating KS4x-1

Operation
Start condition: w Rest condition For process evaluation, a stable condition is required. Therefore, the controller waits until the process has reached a stable condition after self-tuning start. The rest condition is considered being reached, when the process value oscillation is smaller than 0,5% of (rnG.H - rnG.L). Set-point reserve After having come to rest with 0% correcting variable or with Y.Lo, the controller requires a sufficient set-point reserve for its self-tuning attempt, in order to avoid overshoot. Sufficient set-point reserve: inverse controller:(with process value<set-point-(10% of SP.Hi - SP.LO) direct controller:(with process value>set-point+ (10% of SP.Hi - SP.LO) 3.5.3 Self-tuning start

Self-tuning start can be locked via BlueControl (engineering tool) ( P.Loc). The operator can start self-tuning at any time. run SP.x For this, keys and must be pressed simulAda taneously. The AdA LED starts blinking. The Err controller outputs 0% or Y.Lo, waits until the process is at rest and starts self-tuning (AdA LED lit permanently). After successful self-tuning, the AdA-LED is off and the controller continues operating with the new control parameters.

126
125

3.5.4 Self-tuning cancellation By the operator: Self-tuning can always be cancelled by the operator. For this, press and key simultaneously. With manual-automatic switch-over configured via key, self-tuning can also be canceled by actuating key. The controller continues operating with the old parameters in automatic mode in the first case and in manual mode in the second case. By the controller: If the Err LED starts blinking whilst self-tuning is running, successful self-tuning is prevented due to the control conditions. In this case, self-tuning was cancelled by the controller. Dependent of control type, the output status is: w 3-pnt. stepping controller: actuator is closed (0% output) w 2-pnt./ 3-pnt./ continuous controller: If self-tuning was started from the automatic mode, the controller output is 0%. With self-tuning started from manual mode, the controller output is Y2.

Operating KS4x-1

15

Self-tuning

Operation
3.5.5 Acknowledgement procedures in case of unsuccessful self-tuning 1. Press keys and simultaneously: The controller continues controlling using the old parameters in automatic mode. The Err LED continues blinking, until the self-tuning error was acknowledged in the error list. 2. Press key (if configured): The controller goes to manual mode. The Err LED continues blinking, until the self-tuning error was acknowleged in the error list. 3. Press key : Display of error list at extended operating level. After acknowledgement of the error message, the controller continues control in automatic mode using the old parameters. Cancellation causes: r page 13: "Error status self-tuning heating ( ADA.H) and cooling ( ADA.C)"

3.5.6 Examples for self-tuning attempts (controller inverse, heating or heating/cooling) Start: heating power switched on Heating power Y is switched off (1). When the change of process value X was constant during one minute (2), the power is switched on (3). At the reversal point, the self-tuning attempt is finished and the new parameter are used for controlling to set-point W. Start: heating power switched off The controller waits 1,5 minutes (1). Heating power Y is switched on (2). At the reversal point, the self-tuning attempt is finished and control to the set-point is using the new parameters.
X W

100% Y 0% Start r

t reversal point

blinks

X W

100% Y 0% start r

t reversal point

blinks

Self-tuning

16

Operating KS4x-1

Operation

Start: at set-point Heating power Y is switched off (1). If the change of process value X was constant during one minute and the control deviation is > 10% of SP.Hi SP.LO (2), the power is switched on (3). At the reversal point, the self-tuning attempt is finished, and control to set-point W is using the new parameters.

X W

2
t

100% Y 0% start r

t reversal point

blinks

X Three-point controller W The parameters for heating and cooling are determined in two attempts. t reversal point 1 The heating power is switched on t (1). At reversal point 1, heating para- +100% Y 0% -100% meters Pb1, ti1, td1 and t1 1 start r 2 3 t reversal point 2 are determined. The process value is lined out to the set-point (2). The cooling power is switched on (3). At reversal point 2, parameters Pb2, ti2, td2 and t2 are determined and the self-tuning attempt is finished. Control to set-point W is using the new parameters.

3.6 Manual tuning

The optimization aid should be used with units on which the control parameters shall be set without self-tuning. For this, the response of process variable x after a step change of correcting variable y can be used. Frequently, plotting the complete response curve (0 to 100%) is not possible, because the process must be kept within defined limits. Values Tg and xmax (step change from 0 to 100 %) or Dt and Dx (partial step response) can be used to determine the maximum rate of increase vmax.
100% y Yh 0% x Xmax Tg t

y Yh Tu Tg Xmax

= = = = =

correcting variable control range delay time (s) recovery time (s) maximum process value Xmax { x = max. rate of = {t Tg increase of process value

{X {t Tu t

Vmax =

Operating KS4x-1

17

Manual tuning

Operation
The control parameters can be determined from the values calculated for delay time Tu , maximum rate of increase vmax, control range Xh and characteristic K according to the formulas given below. Increase Xp, if line-out to the set-point oscillates.

Parameter adjustment effects

Parameter lower lower lower Control reduced damping increased damping reduced damping Line-out of disturbances slower line-out faster line-out Start-up behaviour slower reduction of duty cycle faster reduction of duty cycle Pb1 higher increased damping td1 higher reduced damping ti1 higher increased damping

faster response to disturbances faster reduction of duty cycle slower response to disturbances slower reduction of duty cycle slower line-out faster line-out slower reduction of duty cycle faster reduction of duty cycle

Formulas
controller behavior PID With 2-point and PD 3-point controllers, the cycle time must be PI P adjusted to t1 / t2 0,25 * Tu 3-point-stepping K = Vmax * Tu Pb1 [phy. units] 1,7 * K 0,5 * K 2,6 * K K 1,7 * K td1 [s] 2 * Tu Tu OFF OFF Tu ti1 [s] 2 * Tu OFF 6 * Tu OFF 2 * Tu

3.7 Alarm handling

Max. three alarms can be configured and assigned to the individual outputs. Generally, outputs OuT.1... OuT.3 can be used each for alarm signalling. If more than one signal is linked to one output the signals are OR linked. Each of the 3 limit values Lim.1 Lim.3 has 2 trigger points H.x (Max) and L.x (Min), which can be switched off individually (parameter = OFF). Switching difference HYS.x of each limit value is adjustable.

Alarm handling

18

Operating KS4x-1

Operation

Operaing principle absolut alarm L.1 = OFF

InL.1 H.1 HYS.1 LED InH.1

* Operating principle relative alarm L.1 = OFF

SP

InL.1 H.1 HYS.1

InH.1

LED

H.1 = OFF
InL.1 L.1 HYS.1 InH.1
InL.1

H.1 = OFF
SP

InH.1 L.1 HYS.1

LED

LED

InL.1 H.1 L.1 HYS.1 HYS.1

InH.1

SP

InL.1 L.1 HYS.1 H.1 HYS.1

InH.1

LED

LED

LED

LED

1: normally closed ( ConF/ Out.x / O.Act=1 ) 2: normally open ( ConF/ Out.x / O.Act= 0 )

The variable to be monitored can be selected seperately for each alarm via configuration The following variables can be monitored: w process value w control deviation xw (process value - set-point) w control deviation xw + suppression after start-up or set-point change w effective set-point Weff w correcting variable y (controller output)

Operating KS4x-1

19

Alarm handling

Operation

If measured value monitoring + alarm status storage is chosen ( ConF / Lim / Fnc.x = 2), the alarm relay remains switched on until the alarm is resetted in the error list ( Lim 1..3 = 1).

3.8 Operating structure

After supply voltage switch-on, the controller starts with the operating levels. The controller status is as before power off.

126
125

3 sec.

PArA

126

ConF

PASS

126

126
CAL

PASS

126
End

PASS

g g

PArA - level: ConF - level: .

At PArA - level, the right decimal point of the upper display line is lit continuously. At ConF - level, the right decimal point of the upper display line blinks

When safety switch Loc is open, only the levels enabled by mePASS ans of BlueControl (engineering tool) are visible and accessible by entry of the password adjusted by means of BlueControl (engineering tool). Individual parameters accessible without password must be copied to the extended operating level. Factory setting:
Safety switch Loc closed open open open

Safety switch Loc closed: all levels accessible without restriction, password PASS = OFF.
Function disabled or enabled with BluePort disabled / enabled disabled enabled enabled Access via the instrument front panel: enabled disabled enabled enabled after password entry

Password entered with BluePort OFF / password OFF / password OFF Password

Operating structure

20

Operating KS4x-1

Configuration level

4 Configuration level 4.1 Configuration survey

ConF Configuration level
Cntr Control and self-tuning

Lim Limit value functions

Othr Display, operation, interface

LOGI Digital inputs

OUt.1 Output 1 OUt.2 Output 2 OUt.3 Output 3

InP.1 Input 1

InP.2 Input 2

SP.Fn StYP I.Fnc Fnc.1 O.Act b.ti S.Lin StYP Src.1 Y.1
C.Fnc Corr mAn C.Act FAIL rnG.L rnG.H Fnc.2 Y.2 Src.2 Lim.1 Fnc.3 Lim.2 Src.3 Lim.3 HC.AL LP.AL LP.AL HC.AL
HC.SC time P.End FAi.1 FAi.2

O.tYP O.Act Y.1 Y.2 Lim.1 Lim.2 Lim.3 LP.AL HC.AL HC.SC time P.End FAi.1 FAi.2 OuT.0 Out.1 O.Src

L_r bAud SP.2 Addr SP.E PrtY Y.2 dELY mAn Unit C.oFF dP m.Loc C.dEl Err.r P.run di.Fn

Adjustment: w The configuratiuons can be adjusted by means of keys . w Transition to the next configuration is by pressing key . w After the last configuration of a group, donE is displayed and followed by automatic change to the next group

Return to the beginning of a group is by pressing the key for 3 sec.

Operating KS4x-1

See output 1

21

Configuration survey

End

Configuration level

4.2 Configuration

Cntr
Name

SP.Fn

b.ti C.Fnc

mAn C.Act FAIL

rnG.L rnG.H Adt0

Value range Description Default 0 Basic configuration of setpoint processing 0 set-point controller can be switched over to external set-point ( LOGI/SP.E) 1 program controller 2 timer, mode 1(bandwidth-controlled, switched off at the end) 3 timer, mode 2 (bandwidth-controlled, set-point remains active at the end) 4 timer, mode 3 (switched off at the end) 5 timer, mode 4 (set-point remains active at the end) 6 timer, mode 5 (switch-on delay) 7 timer, mode 6 (set-point switch-over) 0...9999 5 Timer tolerance band for timer mode 1, 2 and 6. The timer starts when process value = setpoint b.ti 1 Control behaviour (algorithm) 0 on/off controller or signaller with one output 1 PID controller (2-point and continuous) 2 D / Y / Off, or 2-point controller with partial/full load switch-over 3 2 x PID (3-point and continuous) 4 3-point stepping controller 0 Manual operation permitted 0 no 1 yes (see also LOGI/ mAn) 0 Method of controller operation 0 inverse, e.g. heating 1 direct, e.g. cooling 1 Behaviour at sensor break 0 controller outputs switched off 1 y = Y2 2 y = mean output. The maximum permissible output can be adjusted with parameter Ym.H. To prevent determination of inadmissible values, mean value formation is only if the control deviation is lower than parameter L.Ym. -1999...9999 X0 (low limit range of control) 1 0 -1999...9999 X100 (high limit range of control) 1 900 0 Optimization of T1, T2 (only visible with BlueControl!) 0 Automatic optimization 1 No optimization

1 rnG.L and rnG.H are indicating the range of control on which e.g. the self-tuning is refering

Configuration

22

Operating KS4x-1

Configuration level

InP.1
Name Value range Description Default 1 Sensor type selection 0 thermocouple type L (-100...900C) , Fe-CuNi DIN 1 thermocouple type J (-100...1200C) , Fe-CuNi 2 thermocouple type K (-100...1350C), NiCr-Ni thermocouple type N (-100...1300C), Nicrosil-Nisil 3 thermocouple type S (0...1760C), PtRh-Pt10% 4 thermocouple type R (0...1760C), PtRh-Pt13% 5 20 Pt100 (-200.0 ... 100,0 C) 21 Pt100 (-200.0 ... 850,0 C) 22 Pt1000 (-200.0 ... 200.0 C) 23 special 0...4500 Ohm (pre-defined as KTY11-6) 30 0...20mA / 4...20mA 1 40 0...10V / 2...10V 1 0 S.Lin Linearization (only at S.tYP = 23 (KTY 11-6), 30 (0..20mA) and 40 (0..10V) adjustable) 0 none 1 Linearization to specification. Creation of linearization table withBlueControl (engineering tool) possible. The characteristic for KTY 11-6 temperature sensors is preset. 0 Corr Measured value correction / scaling 0 Without scaling 1 Offset correction (at CAL level) 2 2-point correction (at CAL level) 3 Scaling (at PArA level) 0 Forcing INP1 (only visible with BlueControl!) fAI1 0 No forcing 1 Forcing via serial interface

S.tYP

InP.2
Name Value range Description I.Fnc Function selection of INP2 0 no function (subsequent input data are skipped) 1 heating current input 2 external set-point (SP.E) S.tYP Sensor type selection 30 0...20mA / 4...20mA 1 31 0...50mA AC 1 Forcing INP2 (only visible with BlueControl!) fAI2 0 No forcing 1 Forcing via serial interface Default
1

31

Configuration

23

Operating KS4x-1

Configuration level

Lim
Name

Fnc.1 Fnc.2 Fnc.3 Src.1 Src.2 Src.3

HC.AL

LP.AL

Hour Swit

Value range Description Default 1 Function of limit 1/2/3 0 switched off 1 measured value monitoring 2 Measured value monitoring + alarm status storage. A stored limit value can be reset via error list, -key or a digital input ( LOGI/ Err.r). 1 Source of limit 1/2/3 0 process value 1 control deviation xw (process value - set-point) 2 control deviation xw (with suppression after start-up and set-point change) 6 effective set-point Weff 7 correcting variable y (controller output) 0 Alarm heat current function (INP2) 0 switched off 1 Overload short circuit monitoring 2 Break and short circuit monitoring 0 Monitoring of control loop interruption for heating 0 switched off / inactive 1 active If ti1=0 LOOP alarm is inactive! OFF..999999 Operating hours (only visible with BlueControl!) OFF OFF..999999 Output switching cycles (only visible with BlueControl!) OFF

Out.1
Name

O.Act Y.1 Y.2 Lim.1 Lim.2 Lim.3 LP.AL HC.AL

Value range Description Method of operation of output OUT1 0 direct / normally open 1 inverse / normally closed Controller output Y1/Y2 0 not active 1 active Limit 1/2/3 signal 0 not active 1 active Interruption alarm signal (LOOP) 0 not active 1 active Heat current alarm signal 0 not active 1 active

Default
0

1 with current and voltage input signals, scaling is required (see chapter 5.3)

Resetting the controller configuration to factory setting (Default) r chapter 12.1 (page 56)
24 Operating KS4x-1

Configuration

Configuration level

Name

HC.SC timE P.End FAi.1 FAi.2 fOut

Value range Description Solid state relay (SSR) short circuit signal 0 not active 1 active Timer end signal 0 not active 1 active Programmer end signal 0 not active 1 active INP1/ INP2 error signal 0 not active 1 active Forcing OUT1 (only visible with BlueControl!) 0 No forcing 1 Forcing via serial interface

Default
0

Out.2
Configuration parameters Out.2 as Out.1 except for: Default Y.1 = 0 Y.2 = 1

Out.3
Name

O.tYP

O.Act

Y.1 Y.2 Lim.1 Lim.2 Lim.3 LP.AL

HC.AL

Value range Description Default 0 Signal type selection OUT3 0 relay / logic (only visible with current/logic voltage) 1 0 ... 20 mA continuous (only visible with current/logic/volt.) 2 4 ... 20 mA continuous (only visible with current/logic/volt.) 3 0...10 V continuous (only visible with current/logic/voltage) 4 2...10 V continuous (only visible with current/logic/voltage) 5 transmitter supply (only visible without OPTION) 1 Method of operation of output OUT3 (only visible when O.TYP=0) 0 direct / normally open 1 inverse / normally closed 0 Controller output Y1/Y2 (only visible when O.TYP=0) 0 not active 1 active 1 Limit 1/2/3 signal (only visible when O.TYP=0) 0 not active 1 active 0 Interruption alarm signal (LOOP) (only visible when O.TYP=0) 0 not active 1 active 0 Heat current alarm signal (only visible when O.TYP=0) 0 not active 1 active

Operating KS4x-1

25

Configuration

Configuration level

Name

HC.SC

timE P.End FAi.1 FAi.2 Out.0 Out.1 O.Src

fOut

Value range Description Default 0 Solid state relay (SSR) short circuit signal (only visible when O.TYP=0) 0 not active 1 active 0 Timer end signal (only visible when O.TYP=0) 0 not active 1 active 0 Programmer end signal (only visible when O.TYP=0) 0 not active 1 active 1 INP1/ INP2 error (only visible when O.TYP=0) 0 not active 1 active -1999...9999 Scaling of the analog output for 0% (0/4mA or 0/2V, only 0 visible when O.TYP=1..5) -1999...9999 Scaling of the analog output for 100% (20mA or 10V, only 100 visible when O.TYP=1..5) 1 Signal source of the analog output OUT3 (only visible when O.TYP=1..5) 0 not used 1 controller output y1 (continuous) 2 controller output y2 (continuous) 3 process value 4 effective set-point Weff 5 control deviation xw (process value - set-point) 0 Forcing OUT3 (only visible with BlueControl!) 0 No forcing 1 Forcing via serial interface

Method of operation and usage of output Out.1 to Out.3: Is more than one signal chosen active as source, those signals are OR-linked.

LOGI
Name

L_r

SP.2

Value range Description Default 0 Local / Remote switching (Remote: adjusting of all values by front keys is blocked) 0 no function (switch-over via interface is possible) 1 active 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION) 0 Switching to second setpoint SP.2 0 no function (switch-over via interface is possible) 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION)

Configuration

26

Operating KS4x-1

Configuration level

Name

SP.E

Y2

mAn

C.oFF

m.Loc

Err.r

P.run

di.Fn

fDI1

Value range Description Switching to external setpoint SP.E 0 no function (switch-over via interface is possible) 1 active 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION) Y/Y2 switching 0 no function (switch-over via interface is possible) 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION) 6 key Automatic/manual switching 0 no function (switch-over via interface is possible) 1 always activated (manual station) 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION) 6 key Switching off the controller 0 no function (switch-over via interface is possible) 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION) 6 key Blockage of hand function 0 no function (switch-over via interface is possible) 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION) Reset of all error list entries 0 no function (switch-over via interface is possible) 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION) 6 key Programmer Run/Stop (see page 44) 0 no function (switch-over via interface is possible) 2 DI1 3 DI2 (only visible with OPTION) 4 DI3 (only visible with OPTION) Function of digital inputs (valid for all inputs) 0 direct 1 inverse 2 toggle key function Forcing di1 (only visible with BlueControl!) 0 No forcing 1 Forcing via serial interface
27

Default
0

Operating KS4x-1

Configuration

Configuration level
Name Value range Description Forcing di2 (only visible with BlueControl!) 0 No forcing 1 Forcing via serial interface Forcing di3 (only visible with BlueControl!) 0 No forcing 1 Forcing via serial interface Default
0

fDI2 fDI3

othr
Name

bAud

Addr PrtY

dELY Unit

dP

C.dEl FrEq ICof IAda IExo

Pass

Value range Description Baudrate of the interface (only visible with OPTION) 0 2400 Baud 1 4800 Baud 2 9600 Baud 3 19200 Baud 1...247 Address on the interace (only visible with OPTION) Parity (only visible with OPTION) 0 no parity (2 stop bits) 1 even parity 2 odd parity 0...200 Delay of response signal [ms] (only visible with OPTION) Unit 0 without unit 1 C 2 F Decimal point (max. number of digits behind the decimal point) 0 no digit behind the decimal point 1 1 digit behind the decimal point 2 2 digits behind the decimal point 3 3 digits behind the decimal point 0..200 Modem delay [ms] Switching 50 Hz / 60 Hz (only visible with BlueControl!) 0 50 Hz 1 60 Hz Block controller off (only visible with BlueControl!) 0 Released 1 Blocked Block auto tuning (only visible with BlueControl!) 0 Released 1 Blocked Block extended operating level (only visible with BlueControl!) 0 Released 1 Blocked OFF...9999 Password (only visible with BlueControl!)

Default
2

1 1

0 1

0 0

OFF

Configuration

28

Operating KS4x-1

Configuration level

Name

IPar ICnf ICal

Value range Description Block parameter level (only visible with BlueControl!) 0 Released 1 Blocked Block configuration level (only visible with BlueControl!) 0 Released 1 Block Block calibration level (only visible with BlueControl!) 0 Released 1 Blocked

Default
1

+ BlueControl - the engineering tool for the BluePort

controller series 3 engineering tools with different functionality facilitating KS4x-1 configuration and parameter setting are available (see chapter 10: Accessory equipment with ordering information). In addition to configuration and parameter setting, the engineering tools are used for data acquisition and offer long-term storage and print functions. The engineering tools are connected to KS4x-1 via the front-panel interface "BluePort " by means of PC (Windows 95 / 98 / NT) and a PC adaptor. Description BlueControl: see chapter 9: BlueControl (page 49) The set-point processing structure is shown in the following picture:

4.3 Set-point processing

SP.x

126
125

Xeff internal setpoint

run

Ada Err

programmer

timer external setpoint SP.E INP2

1
2 3 4 5 6 7

SP.Hi

* SP.Lo
limitation

0/4...20 mA

r.SP setpoint
- LED
ramp

actual

2.setpoint SP.2

Index: : int/ext-setpoint switching * : configuration SP.Fn : SP / SP.2 switching

The ramp starts at process value with the following switchings: - int / ext-setpoint switching - SP / SP.2switching - Manual-/ Automatic switching - at power on

Operating KS4x-1

29

Set-point processing

Configuration level

4.4 Configuration examples

4.4.1 On-Off controller / Signaller (inverse)

InL.1
InP.1
100%

SP.LO

SP

SP.Hi InH.1

Out.1
0%

SH

ConF / Cntr:

SP.Fn C.Fnc C.Act O.Act Y.1 SH SP.LO SP.Hi

ConF / Out.1: PArA / Cntr: PArA / SEtP:

set-point controller signaller with one output inverse action (e.g. heating applications) = 0 action Out.1 direct = 1 control output Y1 active = 0...9999 switching difference (symmetrical to the trigger point) = -1999...9999 set-point limit low for Weff = -1999...9999 set-point limit high for Weff

= 0 = 0 = 0

For direct signaller action, the controller action must be changed (ConF / Cntr / C.Act = 1 )

process value

SH
setpoint

output

Configuration examples

30

Operating KS4x-1

Configuration level
4.4.2 2-point controller (inverse)

InL.1
InP.1
100%

SP.LO

SP PB1

SP.Hi InH.1

Out.1
0%

ConF / Cntr:

SP.Fn C.Fnc C.Act O.Act Y.1 Pb1 ti1 td1 t1 SP.LO SP.Hi

= 0 = 1 = 0

ConF / Out.1: PArA / Cntr:

PArA / SEtP:

set-point controller 2-point controller (PID) inverse action (e.g. heating applications) = 0 action Out.1 direct = 1 control output Y1 active = 0,1...9999 proportional band 1 (heating) in units of phys. quantity (e.g. C) = 1...9999 integral time 1 (heating) in sec. = 1...9999 derivative time 1 (heating) in sec. = 0,4...9999 min. cycle time 1 (heating) = -1999...9999 set-point limit low for Weff = -1999...9999 set-point limit high for Weff

For direct action, the controller action must be changed (ConF / Cntr / C.Act = 1 ).

setpoint process value

output

Operating KS4x-1

31

Configuration examples

Configuration level
4.4.3 3-point controller (relay & relay)
InL.1
InP.1
100%

SP.LO PB1

SP PB2

SP.Hi InH.1
100%

Out.1
0%

Out.2
0%

ConF / Cntr:

SP.Fn C.Fnc C.Act O.Act Y.1 Y.2 O.Act Y.1 Y.2 Pb1 Pb2 ti1 ti2 td1 td2 t1 t2 SH SP.LO SP.Hi

= 0 = 3 = 0

ConF / Out.1: ConF / Out.2: PArA / Cntr:

PArA / SEtP:

set-point controller 3-point controller (2xPID) action inverse (e.g. heating applications) = 0 action Out.1 direct = 1 control output Y1 active = 0 control output Y2 not active = 0 action Out.2 direct = 0 control output Y1 not active = 1 control output Y2 active = 0,1...9999 proportional band 1 (heating) in units of phys. quantity (e.g. C) = 0,1...9999 proportional band 2 (cooling) in units of phys. quantity (e.g. C) = 1...9999 integral time 1 (heating) in sec. = 1...9999 derivative time 2 (cooling) in sec. = 1...9999 integral time 1 (heating) in sec. = 1...9999 derivative time 2 (cooling) in sec. = 0,4...9999 min. cycle time 1 (heating) = 0,4...9999 min. cycle time 2 (cooling) = 0...9999 neutr. zone in units of phys.quantity = -1999...9999 set-point limit low for Weff = -1999...9999 set-point limit high for Weff

Configuration examples

32

Operating KS4x-1

Configuration level
4.4.4 3-point stepping controller (relay & relay)
InL.1
InP.1
100%

SP.LO PB1

SP

SP.Hi InH.1
100%

Out.1
0%

SH

Out.2
0%

ConF / Cntr:

SP.Fn C.Fnc C.Act O.Act Y.1 Y.2 O.Act Y.1 Y.2 Pb1 ti1 td1 t1 SH tP tt SP.LO SP.Hi

= 0 = 4 = 0 = = = = = = = = = = = = = = =

ConF / Out.1: ConF / Out.2: PArA / Cntr:

PArA / SEtP:

set-point controller 3-point stepping controller inverse action (e.g. heating applications) 0 action Out.1 direct 1 control output Y1 active 0 control output Y2 not active 0 action Out.2 direct 0 control output Y1 not active 1 control output Y2 active 0,1...9999 proportional band 1 (heating) in units of phys. quantity (e.g. C) 1...9999 integral time 1 (heating) in sec. 1...9999 derivative time 1 (heating) in sec. 0,4...9999 min. cycle time 1 (heating) 0...9999 neutral zone in units of phy. quantity 0,1...9999 min. pulse length in sec. 3...9999 actuator travel time in sec. -1999...9999 set-point limit low for Weff -1999...9999 set-point limit high for Weff

For direct action of the 3-point stepping controller, the controller output action must be changed ( ConF / Cntr / C.Act = 1 ).

setpoint process value

output 1 output 2

Operating KS4x-1

33

Configuration examples

Configuration level
4.4.5 Continuous controller (inverse)

InL.1
InP.1
20 mA

SP.LO PB1

SP

SP.Hi InH.1

Out.3
0/4 mA

ConF / Cntr:

SP.Fn C.Fnc C.Act O.tYP Out.0 Out.1 Pb1 ti1 td1 t1 SP.LO SP.Hi

= 0 = 1 = 0 = = = = = = = = = 1/2 -1999...9999 -1999...9999 0,1...9999 1...9999 1...9999 0,4...9999 -1999...9999 -1999...9999

ConF / Out.3: PArA / Cntr:

PArA / SEtP:

set-point controller continuous controller (PID) inverse action (e.g. heating applications) Out.3 type ( 0/4 20mA ) scaling analog output 0/4mA scaling analog output 20mA proportional band 1 (heating) in units of phys. quantity (e.g. C) integral time 1 (heating) in sec. derivative time 1 (heating) in sec. min. cycle time 1 (heating) set-point limit low for Weff set-point limit high for Weff

g g

For direct action of the continuous controller, the controller action must be changed ( ConF / Cntr / C.Act = 1 ). To prevent control outputs Out.1 and Out.2 of the continuous controller from switching simultaneously, the control function of outputs Out.1 and Out.2 must be switched off ( ConF / Out.1 and Out.2 / Y.1 and Y.2 = 0 ).

Configuration examples

34

Operating KS4x-1

Configuration level

4.4.6 D - Y - Off controller / 2-point controller with pre-contact

InL.1
InP.1
100%

SP.LO

SP PB1

SP.Hi InH.1

Out.1
0%

Out.2 SH
ConF / Cntr: SP.Fn C.Fnc C.Act O.Act Y.1 Y.2 O.Act Y.1 Y.2 Pb1 ti1 td1 t1 SH d.SP PArA / SEtP: SP.LO SP.Hi

d.SP
= 0 = 2 = 0 set-point controller D -Y-Off controller inverse action (e.g. heating applications) = 0 action Out.1 direct = 1 control output Y1 active = 0 control output Y2 not active = 0 action Out.2 direct = 0 control output Y1 not active = 1 control output Y2 active = 0,1...9999 proportional band 1 (heating) in units of phys. quantity (e.g. C) = 1...9999 integral time 1 (heating) in sec. = 1...9999 derivative time 1 (heating) in sec. = 0,4...9999 min. cycle time 1 (heating) = 0...9999 switching difference = -1999...9999 trigg. point separation suppl. cont. D / Y / Off in units of phys. quantity = -1999...9999 set-point limit low for Weff = -1999...9999 set-point limit high for Weff

ConF / Out.1: ConF / Out.2: PArA / Cntr:

Operating KS4x-1

35

Configuration examples

Configuration level
4.4.7 KS4x-1 with measured value output
phys. quantity

Out.1

phys. quantity

mA / V

Out.0
0/4mA 0/2V 20mA 10V

1 2 3 4 5

L N

} 90...250VAC 24VUC

6
7
U

OUT3

9 10 11 12 13 14 15

INP1
+
= = = = = 1 2 3 4 -1999...9999 Out.3 0...20mA continuous Out.3 4...20mA continuous Out.3 0...10V continuous Out.3 2...10V continuous scaling Out.3 for 0/4mA or 0/2V scaling Out.3 for 20mA or 10V signal source for Out.3 is the process value

ConF / Out.3:

O.tYP

Out.0 Out.1 O.Src

= -1999...9999 = 3

Configuration examples

36

Operating KS4x-1

Parameter setting level

5 Parameter setting level 5.1 Parameter survey

PArA Parameter setting level SEtP Set-point and process value

Limit value functions

Cntr Control and self-tuning

Input 1
InP.1

Programmer

InP.2

Prog

Input 2

Lim

Pb1 Pb2 ti1 ti2 td1 td2 t1 t2 SH d.SP tP tt Y2 Y.Lo Y.Hi Y0 Ym.H L.Ym

SP.Lo SP.Hi SP.2 r.SP t.SP

SP.01 Pt.01 SP.02 Pt.02 SP.03 Pt.03 SP.04 Pt.04

InL.1 OuL.1 InH.1 OuH.1 tF.1

Inl.2 OuL.2 InH.2 OuH.2

L.1 H.1 HYS.1 L.2 H.2 HYS.2 dEl.2 L.3 H.3 HYS.3 HC.A

Adjustment: w The parameters can be adjusted by means of keys w Transition to the next parameter is by pressing key w After the last parameter of a group, donE is displayed, followed by automatic change to the next group.

g g

Return to the beginning of a group is by pressing the key for 3 sec. If for 30 sec. no keypress is excecuted the controler returns to the process value and setpoint display ( Time Out = 30 sec. )

Parameter survey

End 37

Operating KS4x-1

Parameter setting level

5.2 Parameters

Cntr
Name

Pb1 Pb2 ti1 ti2 td1 td2 t1 t2 SH d.SP tP tt Y2 Y.Lo Y.Hi Y.0 Ym.H L.Ym

Value range Description Default 1...9999 1 Proportional band 1/2 (heating) in phys. dimensions (e.g. C) 100 1...9999 1 Proportional band 2 (cooling) in phys. dimensions (e.g. C) 100 1...9999 180 Integral action time 1 (heating) [s] 1...9999 180 Integral action time 2 (cooling) [s] 1...9999 180 Derivative action time 1 (heating) [s] 1...9999 180 Derivative action time 2 (cooling) [s] 0,4...9999 Minimal cycle duration 1/2 (heating/cooling) [s]. The minimum 10 impulse is 1/4 x t1/t2 0...9999 2 Dead zone or switching differential for on-off control [phys. dimensions) -1999...9999 Trigger point speration for series contact D / Y / Off [phys. 100 dimensions] 0,1...9999 Minimum impulse [s] OFF 3...9999 60 Actuator response time for servo-motor [s] -120...120 2. correcting variable 0 -120...120 Lower output limit [%] 0 -120...120 Upper output limit [%] 100 -120...120 Working point for the correcting variable [%] 0 -120...120 Limitation of the mean value Ym [%] 5 0...9999 8 Max. deviation xw at the start of mean value calculation [phys. dimensions]

Valid for ConF/ othr/ DP = 0. At DP = 1/ 2/ 3 also 0,1 / 0,01 / 0,001.

Value range Description -1999...9999 Set-point limit low for Weff -1999...9999 Set-point limit high for Weff -1999...9999 Set-point 2. 0...9999 Set-point gradient [/min] 0...9999 Timer time [min] -1999...9999 Set-point (only visible with BlueControl!) Default
0 900 0 OFF 5 0

SEtP
Name

SP.LO SP.Hi SP.2 r.SP t.SP SP

ProG
Name

SP.01 Pt.01 SP.02 Pt.02 SP.03 Pt.03

Value range Description -1999...9999 Segment end set-point 1 0...9999 Segment time 1 [min] -1999...9999 Segment end set-point 2 0...9999 Segment time 2 [min] -1999...9999 Segment end set-point 3 0...9999 Segment time 3 [min]

Default
100 1 10 2 100 1 10 2 200 1 10 2

Operating KS4x-1

38

Parameters

Parameter setting level

SP.04 -1999...9999 Segment end set-point 4 0...9999 Pt.04 Segment time 4 [min] 1 If SP.01 SP.04 = OFF then following parameters are not shown 2 If segment end set-point = OFF then the segment time is not visible

Name

Value range Description

Default
200 1 10 2

InP.1
Name

InL.1 OuL.1 InH.1 OuH.1 t.F1

Value range Description -1999...9999 Input value for the lower scaling point -1999...9999 Displayed value for the lower scaling point -1999...9999 Input value for the upper scaling point -1999...9999 Displayed value for the lower scaling point -1999...9999 Filter time constant [s]

Default
0 0 20 20 0,5

InP.2
Name

InL.2 OuL.2 InH.2 OuH.2

Value range Description -1999...9999 Input value for the lower scaling point -1999...9999 Displayed value for the lower scaling point -1999...9999 Input value for the upper scaling point -1999...9999 Displayed value for the upper scaling point

Default
0 0 50 50

Lim
Name

L.1 H.1 HYS.1 L.2 H.2 HYS.2 L.3 H.3 HYS.3 HC.A

Value range Description -1999...9999 Lower limit 1 -1999...9999 Upper limit 1 0...9999 Hysteresis limit 1 -1999...9999 Lower limit 2 -1999...9999 Upper limit 2 0...9999 Hysteresis limit 2 -1999...9999 Lower limit 3 -1999...9999 Upper limit 3 0...9999 Hysteresis limit 3 -1999...9999 Heat current control limit [A]

Default
-10 10 1 OFF OFF 1 OFF OFF 1 50

Resetting the controller configuration to factory setting (Default) r chapter 12.1 (page 56)

Operating KS4x-1

39

Parameters

Parameter setting level

5.3 Input scaling

When using current or voltage signals as input variables for InP.1 or InP.2, scaling of input and display values at parameter setting level is required. Specification of the input value for lower and higher scaling point is in the relevant electrical unit (mA / V).
phys. quantity

OuH.x

mA / V

phys. quantity

OuL.x InL.x InH.x mA/V

5.3.1 Input Inp.1

Parameters InL.1 , OuL.1, InH.1 and OuH.1 are only visible if ConF / InP.1 / Corr = 3 is chosen.
S.tYP 30 (0...20mA) 40 (0...10V) Input signal 0 20 mA 4 20 mA 0 10 V 2 10 V InL.1 0 4 0 2 OuL.1 any any any any InH.1 20 20 10 10 OuH.1 any any any any

In addition to these settings, InL.1 and InH.1 can be adjusted in the range (0...20mA / 0...10V) determined by selection of S.tYP . predetermined scaling resistance a For using the (Pt100), the settings forwith thermocouple and and for InH.1 and thermometer InL.1 and OuL.1 OuH.1 must have the same value.

Input scaling changes at calibration level (r page 41) are displayed by input scaling at parameter setting level. After calibration reset (OFF), the scaling parameters are reset to default.
S.tYP 30 31 Input signal 0 20 mA 0 50 mA InL.2 0 0 OuL2 any any InH.2 20 50 OuH.2 any any

5.3.2 Input InP.2

In addition to these settings, InL.2 and InH.2 can be adjusted in the range (0...20/ 50mA) determined by selection of S.tYP.

Input scaling

40

Operating KS4x-1

Calibration level

6 Calibration level

Measured value correction ( CAL) is only visible if ConF / InP.1 / Corr = 1 or 2 is chosen. The measured value can be matched in the calibration menu ( CAL). Two methods are available: Offset correction
( ConF/ InP.1 / Corr =1 ):
display standard setting offset correction

w possible on-line at the process

OuL.1new

OuL.1old

InL.1

2-point correction
( ConF/ InP.1 / Corr = 2 ):
display standard setting 2-point correction

w is possible off-line with process value simulator

OuH.1old OuH.1new

OuL.1new OuL.1old InL.1 InH.1 X

Operating KS4x-1

41

Calibration level
Offset correction ( ConF/ InP.1 / Corr =1 ):

SP.X

126
125

InL.1: The input value of the scaling point is displayed. The operator must wait, until the process is at rest. Subsequently, the operator acknowledges the input value by pressing key . OuL.1: The display value of the scaling point is displayed. Before calibration, OuL.1 is equal to InL.1. The operator can correct the display value by pressing keys . Subsequently, he confirms the display value by pressing key .

r
run
Ada

Err

r r PArA 3 sec.

:
CAL r

r InP.1 r r InL.1 r r OuL.1 r r End r

42

Operating KS4x-1

Calibration level
2-point correction ( ConF/ InP.1 / Corr =1 ):

SP.X

126 r r
125
run
Ada

InL.1: The input value of the lower scaling point is displayed. The operator must adjust the lower input value by means of a process value simulator and confirm the input value by pressing key . OuL.1: The display value of the lower scaling point is displayed. Before calibration, OuL.1 equals InL.1. The operator can correct the lower display value by pressing the keys. Subsequently, he confirms the display value by pressing key . InH.1: The input value of the upper scaling point is displayed. . The operator must adjust the upper input value by means of the process value simulator and confirm the input value by pressing key . OuH.1: The display value of the upper scaling point is displayed. Before calibration OuH.1 equals InH.1. The operator can correct the upper display value by pressing keys Subsequently, he confirms the display value by pressing key .

r
PArA
Err

3 sec.

:
CAL r

r InP.1 r r InL.1 r r OuL.1 r r InH.1 r r OuH.1 r r End r

The parameters (OuL.1, OuH.1) changed at CAL level can be reset by adjusting the parameters below the lowest adjustment value (OFF) by means of decrement key .

Operating KS4x-1

43

Programmer

7 Programmer
W,X SP.01 SP.02 SP.03 SP.04 W,X W

Pt.01

Pt.02

Pt.03

Pt.04

Programmer set-up: For using the controller as a programmer, select parameter SP.Fn = 1 in the ConF menu (r page 21). The programmer is started via one of digital inputs di1..3. Which input shall be used for starting the programmer is determined by selecting parameter P.run = 2 / 3 / 4 in the ConF menu accordingly. (r page 23). For assigning the program end as a digital signal to one of the relay outputs, parameter P.End = 1 must be selected for the relevant output OUT.1...OUT.3 in the ConF menu (r page 26, 27). Programmer parameter setting: A programmer with 4 segments is available to the user. Determine a segment duration Pt.01 .. Pt.04 (in minutes) and a segment target set-point SP.01 .. SP.04 for each segment in the PArA menu (r page 38). Starting/stopping the programmer: Starting the programmer is done by a digital signal at input di1..3 selected by parameter P.run (r page 23). The programmer calculates a gradient from segment end setpoint and segment time. This gradient is always valid. Normaly, the programmer starts the first segment at process value. Because of this the effective run-time of the first segment may differ from the at PArA level setted segment time (process value setpoint). After program end, the controller continues controlling with the target set-point set last. If the program is stopped during execution (signal at digital input di1..3 is taken away), the programmer returns to program start and waits for a new start signal.

44

Operating KS4x-1

Programmer

+ Program parameter changing while the program is running is possible.

Changing the segment time: Changing the segment time leads to re-calculation of the required gradient. When the segment time has already elapsed, starting with the new segment is done directly, where the set-point changes with a step. Changing the segment end setpoint: Changing the set-point leads to re-calculation of the required gradient, in order to reach the new set-point during the segment rest time, whereby the required gradient polarity sign can change.

Operating KS4x-1

45

Timer

8 Timer 8.1 Setting up the timer

8.1.1 Operating modes 6 different timer modes are available to the user. The relevant timer mode can be set via parameter SP.Fn in the Conf menu (r page 21). Mode 1 () After timer start, control is to the adjusted set-point . The timer (t.SP) runs as soon as the process value enters or leaves the band around the set-point (x = SP _ b.ti). After timer elapse, the controller returns to Y2. End and the set-point are displayed alternately in the lower display line. Mode 2 () Mode 2 corresponds to mode 1, except that control is continued with the relevant set-point after timer (t.SP) elapse. Mode 3 () After timer start, control is to the adjusted set-point. The timer (t.SP) starts immediately after switch-over. After timer elapsing the controller switches off. End and the set-point are displayed alternately in the bottom display line. Mode 4 () Mode 4 corresponds to mode 3, except that control is continued with the relevant set-point after timer (t.SP) elapse. Mode 5 (delay) The timer starts immediately. The controller output remains on Y2. After timer (t.SP) elapse, control starts with the adjusted set-point.

u SP _ b.ti u
run blinks run

SP

2 1
blinks

End

Start

t.SP

SP
run run

4 3
blinks

End

Start

t.SP

SP
run

blinks

End

Start

t.SP

Setting up the timer

46

Operating KS4x-1

Timer

SP blinks Start t.SP

8.1.2 Tolerance band Timer modes 1,2 and 6 are provided with a freely adjustable tolerance band. The tolerance band around the set-point can be adjusted via parameter b.ti in the Conf menu (x = SP.2 _ b.ti ) (r page 21). 8.1.3 Timer start Various procedures for starting the timer are possible:
Start via LOGI Y2 SP.2 = = 2 x 3 x 4 x x 2 x 3 x 4 6 x 0 x x 0 x x 1 d d d d d d Mode 2 3 4 d d d d d d d d d d d d d d d d d d 5 d d d d d d 6 d d d d d

Y / Y2 switch-over via digital input 1 SP / SP.2 switch-over via digital input 1 Pressing key Power On

di1 di2 di3 di1 di2 di3

Changing t.ti (extended operating level) Serial interface (if provided) x x d d d d d d 1 when using a digital input, adjust parameter di.Fn = 2 ( ConF/ LOGI) ( key function) x no effect

Operating KS4x-1

47

u
run run

Mode 6 After set-point switch-over (SPr SP.2), control is to SP.2. The timer (t.SP) starts when the process value enters the adjusted band around the set-point (x = SP.2 _ b.ti). After time elapse the controller returns to SP. End and the set-point are displayed alternately in the lower display line.

SP.2

u SP.2 _ b.ti End SP

Setting up the timer

Timer
8.1.4 Signal end If one of the relays shall switch after timer elapse, parameter TimE = 1 and inverse action O.Act = 1 must be selected for the relevant output OUT.1 OUT.3 in the ConF menu (r page 25, 26). If direct action is selected, the relevant output signals the active timer.

8.2 Determining the timer run-time

The timer run-time can be determined via parameter t.SP in the PArA menu. The timer run-time must be specified in minutes with one digit behind the decimal point (0,1 minutes = 6 seconds). Alternatively, the timer run-time can be determined directly at extended operating level (r chapter 8.3).

8.3 Starting the timer

Dependent of configuration, the timer start is as follows: w by a positive flank at one of digital inputs di1..3 w by pressing key w by switching on the controller (power On) w by changing the timer run-time t.ti > 0 (extended operating level) w via the serial interface Display:
Run LED blinks lit off ( End and setpoint are displayed alternately) Signification - timer was started - timer is not running yet - timer was started - timer is running - timer is off - timer has elapsed - deletion of End display by pressing any key

SP.x

126
125

run

Ada

Err

With active timer, the time can be adjusted by changing parameter t.ti at extended operating level.

Determining the timer run-time

48

Operating KS4x-1

BlueControl

9 BlueControl
BlueControl is the projection environment for the BluePort controller series of PMA. The following 3 versions with graded functionality are available:

The mini version is - free of charge - at your disposal as download at PMA homepage www.pma-online.de or on the PMA-CD (please ask for). At the end of the installation the licence number has to be stated or DEMO mode must be chosen. At DEMO mode the licence number can be stated subsequently under Help r Licence r Change.

Operating KS4x-1

49

Versions

10 Versions
KS 4 1 0 0 00 KS 40-1 (1/8 DIN) 0 KS 41-1 (1/8 DIN "landscape" ) 1 KS 42-1 (1/4 DIN) 2 Flat-pin connectors 0 Screw terminals 1 90..250V AC, 3 relays 0 24VAC / 18..30VDC, 3 relays 1 90..250V AC, 2 relays + mA/logic 2 24VAC / 18..30VDC, 2 relays +mA/logic 3 no option 0 RS422/485 + Transmitter power supply +di2, di3 1 Standard configuration Configuration to specification no manual manual german manual english manual french Standard (CE certified) cULus-certified (with screw terminals only) EN 14597 (replaces DIN 3440) certified GL (German Lloyd) certified GOST-R certified (incl. operating manual)

0 9 0 D E F 0 U D G R

Accessories delivered with the unit Operating manual (if selected by the ordering code) w 2 fixing clamps w operating note in 15 languages Accessory equipment with ordering information
Description Heating current transformer 50A AC PC-adaptor for the front-panel interface Standard rail adaptor Operating manual Operating manual Operating manual Interface description Modbus RTU Interface description Modbus RTU BlueControl (engineering tool) BlueControl (engineering tool) BlueControl (engineering tool) Order no. 9404-407-50001 9407-998-00001 9407-998-00061 9499-040-62718 9499-040-62711 9499-040-62732 9499-040-63518 9499-040-63511 www.pma-online.de 9407-999-11001 9407-999-11011

German English French German English Mini Basic Expert

Download

50

Operating KS4x-1

Technical data 11 Technical data

INPUTS PROCESS VALUE INPUT INP1
Resolution: Decimal point: Dig. input filter: Scanning cycle: Measured value correction: Thermocouples > 14 bits 0 to 3 digits behind the decimal point adjustable 0,000...9999 s 100 ms 2-point or offset correction
via current transformer ( Accessory equipment)

Measuring range: 0...50mA AC Scaling: adjustable -1999...0,000...9999 A Current measuring range

Technical data as for INP1

CONTROL INPUT DI1

Configurable as switch or push-button! Connection of a potential-free contact suitable for switching dry circuits.

r Table 1 (page 53 )
Input resistance: Effect of source resistance:
Cold-junction compensation

Switched voltage: Current: 1 MW 1 mV/W 0,5 K 1 mA

2,5 V 50 mA

CONTROL INPUTS DI2, DI3 (OPTION)

Configurable as switch or push-button! Optocoupler input for active triggering

Maximal additional error:

Sensor break monitoring

Sensor current: Configurable output action Resistance thermometer

Nominal voltage Current sink (IEC 1131 type 1) Logic 0 Logic 1 Current requirement Power:

24 V DC external -3...5 V 15...30 V approx.. 5 mA

r Table 2 (page 53 )
Connection: Lead resistance: Input circuit monitor:

TRANSMITTER SUPPLY UT (OPTION)

22 mA / 18 V
If the universal output OUT3 is used there may be no external galvanic connection between measuring and output circuits!

2 or 3-wire max. 30 Ohm break and short circuit

Special measuring range BlueControl (engineering tool) can be used to match the input to sensor KTY 11-6 (characteristic is stored in the controller).

GALVANIC ISOLATION
Safety isolation Function isolation

Physical measuring range: Linearization segments

0...4500 Ohm 16

Power supply connections

r Table 3 (page 53 )
Span start, end of span: Scaling: Linearization:

Current and voltage signals anywhere within measuring range selectable -1999...9999 16 segments, adaptable with BlueControl Decimal point: adjustable Input circuit monitor: 12,5% below span start (2mA, 1V)

Process value input INP1 Supplementary input INP2 Digital input di1 Relay outputs OUT 1,2 RS422/485 interface Relay output OUT3 Digital inputs di2, 3 Universal output OUT3 Transmitter supply UT

OUTPUTS RELAY OUTPUTS OUT1, OUT2

Contact type: 2 NO contacts with common connection Max. contact rating: 500 VA, 250 V, 2A at 48...62Hz, resistive load Min. contact rating: 6V, 1 mA DC

SUPPLEMENTARY INPUT INP2

Resolution: Scanning cycle: Accuracy: > 14 bits 100 ms < 0,5 %

Heating current measurement

Operating KS4x-1

51

Technical data
Operating life (electr.): 800.000 duty cycles with max. rating

UNIVERSAL SUPPLY 24 V UC

AC voltage: 20,4...26,4 V AC Frequency: 48...62 Hz OUT3 USED AS RELAY OUTPUT DC voltage: 18...31 V DC Contact type: potential-free changeover contact Power consumption: approx.. 7,0 VA Max.contact rating: 500 VA, 250 V, 2A at 48...62Hz, resistive load BEHAVIOUR WITH POWER FAILURE Min. contact rating: 5V, 10 mA AC/DC Configuration, parameters and adjusted Operating life 600.000 duty cycles with max. set-points, control mode: (electr.): contact rating Non-volatile storage in EEPROM
Note: If the relays OUT1...OUT3 operate external contactors, these must be fitted with RC snubber circuits to manufacturer specifications to prevent excessive switch-off voltage peaks.

BLUEPORT FRONT INTERFACE

Connection of PC via PC adapter (see "Accessory equipment"). The BlueControl software is used to configure, set parameters and operate the KS4x-1.

OUT3 AS UNIVERSAL OUTPUT

Galvanically isolated from the inputs.

BUS INTERFACE (OPTION)

Galvanically isolated Physical: RS 422/485 Protocol: Modbus RTU Transmission speed: 2400, 4800, 9600, 19.200 bits/sec Address range: 1...247 Number of controllers per bus: 32 Repeaters must be used to connect a higher number of controllers.

Freely scalable Resolution:

11 bits

Current output 0/4...20 mA configurable. Signal range: 0...approx.22mA Max. load: 500 W Load effect: no effect Resolution: 22 mA (0,1%) Accuracy 40 mA (0,2%) Voltage output 0/2...10V configurable Signal range: 0...11 V Min. load: 2 kW Load effect: no effect Resolution: 11 mV (0,1%) Accuracy 20 mV (0,2%) OUT3 used as transmitter supply Output power: 22 mA / 13 V OUT3 used as logic output Load 500 W 0/ 20 mA Load > 500 W 0/> 13 V

ENVIRONMENTAL CONDITIONS
Protection modes Front panel: IP 65 (NEMA 4X) Housing: IP 20 Terminals: IP 00 Permissible temperatures For specified accuracy: 0...60C Warm-up time: 15 minutes For operation: -20...65C For storage: -40...70C Humidity
75% yearly average, no condensation

Shock and vibration

Vibration test Fc (DIN 68-2-6)

POWER SUPPLY
Dependent of order:

AC SUPPLY
Voltage: Frequency: Power consumption 90...260 V AC 48...62 Hz approx. 7,0 VA

Frequency: 10...150 Hz Unit in operation: 1g or 0,075 mm Unit not in operation: 2g or 0,15 mm

Shock test Ea (DIN IEC 68-2-27)

Shock: Duration:

15g 11ms

52

Operating KS4x-1

Technical data
Electromagnetic compatibility
Complies with EN 61 326-1 (for continuous, non-attended operation)

w Thermal transfer plants with organic transfer

media to DIN 4754 w Oil-heated plants to DIN 4755 cULus-certification (Type 1, indoor use) File: E 208286 GOST-R Certificate(on request): For each shipment to the russian federation and GUS-states, an authenticated certificate is to be delivered with the GOST-R certificated controllers (KS4x-1, KS5x-1, KS9x-1, one certificate per shipment - 9499-047-14465).

GENERAL
Housing Material: Flammability class: Safety test
Complies with EN 61010-1 (VDE 0411-1): Overvoltage category II Contamination class 2 Working voltage range 300 V Protection class II

Makrolon 9415 flame-retardant UL 94 VO, self-extinguishing

Plug-in module, inserted from the front

Mounting
Panel mounting with two fixing clamps at top/bottom or right/left, High-density mounting possible

Certifications
Type tested to EN 14597 (replaces DIN 3440) With certified sensors applicable for:

w Heat generating plants with outflow

temperatures up to 120C to DIN 4751

Mounting position: uncritical Weight: 0,27kg Accessories delivered with the unit
Operating manual Fixing clamps

w Hot-water plants with outflow temperatures

above 110C to DIN 4752

Table 1 Thermocouple measuring ranges

Thermocouple type L Fe-CuNi (DIN) J Fe-CuNi K NiCr-Ni N Nicrosil/Nisil S PtRh-Pt 10% R PtRh-Pt 13% Range -100...900C -100...1200C -100...1350C -100...1300C 0...1760C 0...1760C -148...1652F -148...2192F -148...2462F -148...2372F 32...3200F 32...3200F Accuracy 2K 2K 2K 2K 2K 2K Resolution () 0,1 K 0,1 K 0,2 K 0,2 K 0,2 K 0,2 K

Table 2 Resistance transducer measuring ranges

Type Pt100 Pt100 Pt1000 KTY 11-6 Sens. current 0,2mA Range -200...100C -200...850C -200...850C -50...150C -140...212F -140...1562F -140...1562F -58...302F Accuracy 1K 1K 2K 2K Resolution () 0,1K 0,1K 0,1K 0,05K

Table 3 Current and voltage measuring ranges

Range 0-10 Volt 0-20 mA Input resistance ~ 110 kW 49 W (voltage requirement 2,5 V) Accuracy 0,1 % 0,1 % Resolution () 0,6 mV 1,5 mA

Operating KS4x-1

53

Safety hints

12 Safety hints
This unit was built and tested in compliance with VDE 0411-1 / EN 61010-1 and was delivered in safe condition. The unit complies with European guideline 89/336/EWG (EMC) and is provided with CE marking. The unit was tested before delivery and has passed the tests required by the test schedule. To maintain this condition and to ensure safe operation, the user must follow the hints and warnings given in this operating manual. The unit is intended exclusively for use as a measurement and control instrument in technical installations. Warning a If the unit is damaged to an extent that safe operation seems impossible, the unit must not be taken into operation. ELECTRICAL CONNECTIONS The electrical wiring must conform to local standards (e.g. VDE 0100). The input measurement and control leads must be kept separate from signal and power supply leads. In the installation of the controller a switch or a circuit-breaker must be used and signified. The switch or circuit-breaker must be installed near by the controller and the user must have easy access to the controller. COMMISSIONING Before instrument switch-on, check that the following information is taken into account: w Ensure that the supply voltage corresponds to the specifications on the type label. w All covers required for contact protection must be fitted. w If the controller is connected with other units in the same signal loop, check that the equipment in the output circuit is not affected before switch-on. If necessary, suitable protective measures must be taken. w The unit may be operated only in installed condition. w Before and during operation, the temperature restrictions specified for controller operation must be met. SHUT-DOWN For taking the unit out of operation, disconnect it from all voltage sources and protect it against accidental operation. If the controller is connected with other equipment in the same signal loop, check that other equipment in the output circuit is not affected before switch-off. If necessary, suitable protective measures must be taken.

54

Operating KS4x-1

Safety hints
MAINTENANCE, REPAIR AND MODIFICATION The units do not need particular maintenance. Warning a When opening the units, or when removing covers or components, live parts and terminals may be exposed. Before starting this work, the unit must be disconnected completely. After completing this work, re-shut the unit and re-fit all covers and components. Check if specifications on the type label must be changed and correct them, if necessary.

Caution When opening the units, components which are sensitive to electrostatic discharge (ESD) can be exposed. The following work may be done only at workstations with suitable ESD protection. Modification, maintenance and repair work may be done only by trained and authorized personnel. For this purpose, the PMA service should be contacted.

a The cleaning of the front of the controller should be done with a dry or a wetted (spirit, water) kerchief.

Operating KS4x-1

55

Safety hints

12.1 Resetting to factory setting

In case of faultyconfiguration, KS4x-1 can be reset to the default condition.
1 2 3 4

+ Power on
SP.x

SP.x

FAC
torY

run
Ada

FAC
no

run
Ada

SP.x

FAC
YES

run
Ada

SP.x

FAC
COPY

run
Ada

SP.x

8.8.8.8.
8.8.8.8.

run
Ada

Err

Err

Err

Err

Err

1.

2.

1 For this, the operator must keep the keys increment and decrement pressed during power-on. 2 Then, press key increment to select YES. 3 Confirm factory resetting with Enter and the copy procedure is started (display COPY). 4 Afterwards the device restarts. In all other cases, no reset will occur (timeout abortion).

g g g

If one of the operating levels was blocked and the safety lock is open, reset to factory setting is not possible. If a pass number was defined (via BlueControl ) and the safety lock is open, but no operating level was blocked, enter the correct pass number when prompted in 3. A wrong pass number aborts the reset action. The copy procedure ( COPY) can take some seconds. Now, the transmitter is in normal operation.

Resetting to factory setting

56

Operating KS4x-1

Index 0-9 2-point correction. . . . . . . . . . . . 41 A Alarm handling . . . . . . . . . . 18 - 19 B BlueControl. . . . . . . . . . . . . . . 49 Bus interface Technical Data. . . . . . . . . . 52 C Calibration level (CAL) . . . . . . 41 - 43 Certifications . . . . . . . . . . . . . . 53 Configuration examples 2-point controller . . . . . . . . 31 3-point controller . . . . . . . . 32 3-point stepping controller . . . 33 Continuous controller . . . . . . 34 D - Y -Off controller. . . . . . . 35 Measured value output . . . . . 36 Signaller . . . . . . . . . . . . . 30 Configuration level Configuration parameters. . 22 - 28 Parameter survey . . . . . . . . 21 Connecting diagram . . . . . . . . . . . 6 Connecting examples di2/3, 2-wire transmitter supply . 8 INP2 current transformer . . . . . 7 OUT1/2 heating/cooling . . . . . 7 OUT3 as logic output . . . . . . . 8 OUT3 transmitter supply . . . . . 8 RS485 interface . . . . . . . . . . 9 Control inputs di1, di2, di3 Technical data . . . . . . . . . . 51 Current signal measuring range . . . . 51 D Digital inputs di1, di2, di3 Configuration . . . . . . . . . . 26 Technical data . . . . . . . . . . 51 E Environmental conditions . . . . . . . 53 Equipment . . . . . . . . . . . . . . . 50 Error list . . . . . . . . . . . . . . . . 12
Operating KS4x-1

F Front view . . . . . . . . . . . . . . . 10 I Input INP1 Configuration Parameters . . Technical data Input INP2 Configuration Parameters . . Technical data Input scaling . . . .

. . . . . . . . . . 23 . . . . . . . . . . 39 . . . . . . . . . . 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 39 51 40

K Kalibrierung (CAL) . . . . . . . . . . 41 L LED Ada - LED . . Err - LED . . - LED . . . LED colours . - LED. . . run - LED . . SP.x - LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 10 10 10 10 10 10

M Maintenance manager . . . . . . . 12 - 13 Manual tuning . . . . . . . . . . . . . 17 Mounting. . . . . . . . . . . . . . . . . 5 O Offset correction . . Output OUT1 Configuration Technical data Output OUT2 Configuration Technical data Output OUT3 Configuration Technical data . . . . . . . . . . 41 . . . . . . . . . . 24 . . . . . . . . . . 52 . . . . . . . . . . 25 . . . . . . . . . . 52 . . . . . . . . . . 25 . . . . . . . . . . 52

P Parameter setting level Parameter survey . . . . . . . . 37 Parameters . . . . . . . . . 38 - 39

57

Power supply . . . . . . . . . . . . . Programmer Changing segment end setpoint Changing segment time . . . . Parameter setting . . . . . . . Set-up . . . . . . . . . . . . . Starting/Stopping . . . . . . .

. 52 . . . . . 45 45 44 44 44

R Resetting to factory setting . . . . . . . 56 Resistance thermometer measuring range . . . . . . . . . . . . . . . . . . . . . 51 S Safety hints . . . . . . . . . . . . 55 - 56 Safety switch. . . . . . . . . . . . . . . 5 Safety test. . . . . . . . . . . . . . . . 53 Self-tuning Cancelation . . . . . . . . . . . 15 Cancelation causes. . . . . . . . 16 Start . . . . . . . . . . . . . . . 15 Set-point processing . . . . . . . . . . 29 T Thermocouple measuring range Timer Display run-LED . . . . Operating modes. . . . . Signal end . . . . . . . . Timer start . . . . . . . . Tolerance band . . . . . . . . . 51 . . . . . . . . . . . . . . . . . . . . 48 46 48 47 47

V Versions . . . . . . . . . . . . . . . . 50 Voltage signal measuring range . . . . 51

58

Operating KS4x-1

Operating KS4x-1

59

9499- 040- 62711

Subject to alterations without notice nderungen vorbehalten Sous rserve de toutes modifications

PMA Proze- und Maschinen-Automation GmbH P.O.B. 310 229, D-34058 Kassel, Germany Printed in Germany 9499-040-62711 (05/2009)

A6

A5 auf A6 gefaltet, 2-fach geheftet, SW-Druck Normalpapier wei 80g/m