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Industrial controller KS92/94

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2. Selection menus Parameters End i PHE y tRest z S End tHet End Clock tBrut Weel Prog gt M EI Input i diext Contr OCs Wext End iw Blck2 gt El HO gt RBIc Hob gt 0Blc Elcki OEE Hob gt HBlc HS CBE HOE EEE i Uy End k End t TF6 m Erg Tf gain TFS End A gain Y End be gains TF4 Y End b Ins gt gaind 3 m IHPS EEE zong s2out End InP4 SH gt E szin b H End DEZ viot a Pre o ER No aero HE I f i u 1 i i y End i i Ksh Mma i End i i vadi Tu2 y End Tri 3 End i Lil ER Iborra Tui 3 Tri 2 End x Tul End Klare Tni 3 Tul 2 Tri 1 End d i ORes2 Recon z 3 Tri 2 Tui 1 Tri a Yo y ORes1 Set 3 T 3 xP 2 Tht 4 Tui 8 WEE End Tris3 Erd Set 2 E gt El Sp 1 a Trisz Siml Set 1 H r gt ESE a Trial AL Set A OF L Oss Input al Cara eS Fort Contr dort Tune 4 gt i Limit Ze Prog ly En
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4. End al Sisnl Alena Iar Hust R 1h Input gt End Conte ITOK Hold Tune Han a ars fastar CIRIT sx IM 12 Para Dp e Calibration for Xo Cem 99 Select SC as shown in Fig 12 Press the selector key the CG on the display DC starts blinking Now bring the potentiometric transducer into the position for Xo usually lower end position The instantaneously valid value for INP1 appears on display 1 Press the selector key again to store this actual value as X0 e Calibration for X100 must be done accordingly Select 1 Hc Press the selector key The CG of the display 1c starts blinking Now bring the transducer into the position for X100 usually upper end position The instantaneously valid value for INP1 is shown on display 1 Press the selector key again to store this actual value as X100 Standard 0 4 20 mA signal input The input resistance is 50 Q During configuration distinction of 0 20 mA and 4 20 mA is made For the 4 20 mA standard signal the behaviour with sensor break can be determined d 3 M lt 2 gt oreover the decimal point and thus the digits behind the decimal point are configurable gt 2 81 Additionally a physical input signal scaling by means of Xo and X100 is possible gt 28 and E Z For input value processing a filter time constant with a numeric value within 0 5 an
5. values A A E V4 NAT ae 177 O Ol 1171 COH11 rn d i comi D PHL coma Le IN IN 1 The configuration structure is shown on the two following pages 16 and 17 All possible configuration words are listed Configuration words which are irrelevant for a function are not displayed during the dialogue Switch over to a selection menu is possible from anywhere during configuration by pressing key CO gt 3s End Return to configuration level More Activating the More function x Quit Return to operating level Configuration configuration changes are not effective level Exit Return to operating level configuration changes are effective and the controller is re initialized 95 User manual KS92 94 Fig 753 Survey of configuration Configuration 12 07 2000
6. Panchen INPI INP3 INP4 INPS INP6 C 228 C 328 C 378 C 428 C 478 SCAL X only with KS94 only with KS94 X X CHAR X only with KS94 SQRT X only with KS94 only with KS94 X X LAGI X only with KS94 only with KS94 X X SCAL Scaling CHAR Scaling is done according to equation OUT m INP b Hereby parameters m and b can be adjusted so that inverse characteristics can also be realized Adjustable parameters m gain and b offset Linearization Up to 8 adjustable segment points value pairs xsi ysi can be used to simulate or linearize non linear ys7 functions The number of value pairs vee a is limited to 8 7 segments If less than 8 value pairs are used the first unused segment must be switched off by entry of the xs value into Offset and gradient for the relevant intervals are determined automatically from the adjusted value pairs The segment points are interconnected by straight lines so that there is a defined output value ys for each input value xs Beyond the defined intervals the first or last segment is prolonged Adjustable parameters for each input x1 y1 x2 y2 x8 y8 Note that the input values x values must be entered in ascending order YA ys8 ys4 ys3 ys2 xs1 xs2 xs3 xs4 xs5 xs6 xs7 29 User manual KS92 94 KS92 94 function survey SQRT LAGI User manual KS92 94 Square root The square root
7. di3 used for switch over between local 0 and remote 1 di4 used for switch over between program STOP 0 and START 1 92 SPrSt di5 used for programmer RESET normal 0 reset 1 di6 di7 used for program number selection with programmer 1 di 0 1 x di8 0 1 0 1 di7 0 0 1 di9 0 0 1 1 Programm 1 2 3 Parameter set 0 1 2 3 di7 di8 used for program number selection with programmer dil0 minimum delimitation of the correcting variable with 3 pnt stepping controller dill maximum delimitation of the correcting variable with 3 pnt stepping controller and can be configured for switching on the effective set point offset E 90 Sdlari dil2 switches over bumplessly to the internal set point tracking OFF 0 ON 1 and can be used for switching over to the second set point W2 E 130 OFF 0 ON 1 12 07 2000 15 User manual KS92 94 Electrical connections 3 5 Digital outputs dol to do6 dol indicates the status of control output 1 with programmer do2 indicates the status of control output 2 with programmer do3 indicates the status of control output 3 with programmer do4 indicates the status of control output 4 with programmer do5 indicates if the controller is in manual or automatic mode or the Y1 condition with switching controllers 2 594 do6 indicates if the controller uses the external or the internal set point or status Y2 with switching controllers 4 4 1 3 6 Versi
8. i 60 C S LL switch with the switch closed transition to parameter and configuration level is disabled When making an attempt to change over to the parameter level Para ie displayed text1 Correcting variable set point and parameters at the extended operating level remain available for selecting and changing For access to the S I L switch release the locking screw and withdraw the instrument module from the housing Subsequently re insert the controller module into the housing and mount it with screws A Caution The instrument contains ESD hazarded 12 07 2000 components 92 0 8 max orc 95 rel AAN gt 24 AN User manual KS92 94 Mounting and connection 2 1 1 Removing the controller from the housing For maintenance and service purposes the controller module can be removed from the housing whereby the housing with the relevant wiring remains in the installation If the operating voltage is switched on during this procedure the live terminals in the controller housing must be protected against contact A The controller electronics contains electrostatically sensitive components Static discharge must be Arad prevented by suitable measures When removing several controllers take care that the controllers are re mounted into the correct housings For this not only the hardware but also the data configured in the controll
9. Set point switch over See section from page In general the following set points are possible internal wint second internal set point w2 and external set point Wext With program control external set point wext must be selected The analog set point is provided by the programmer Correcting variable See section from page Particularly suitable for processes where load changes cause process value drops The set point preferential or process value change is load dependent The evaluated and filtered correcting variable is added to the set point User manual KS92 94 130 12 07 2000 12 07 2000 Terminology explanation PIP switch over During optimization of slow processes e g larges furnaces the controller I action can cause problems after start up optimization line out may take a long time With disturbance behaviour optimization there may be considerable overshoot This can be prevented by switching off the I action during start up or in case of high control deviations e g by means of a limit contact which is effective for the control deviation and by switching it on again only after the set point was nearly reached To prevent a permanent control deviation the difference between limit contact and set point must be higher than the permanent control deviation Tracking See section from page Switching over from external or program set point to internal set point can cause set point or correcting variable step chang
10. 6 8 6 8 1 12 07 2000 Set point functions Set point switch over w w2 Wext Wint w wp Controller On Control with the new set point starts linearly from the instantaneous process value The slope of the ramp is determined dependent of direction by Grw Grw or Grw2 This is also valid if the process value at switch over time is out of the adjustable set point range W0 W 100 e g during start up In this case controller On means controller power supply switch on For activating the gradient with controller signal Soff On Drun must be used gt see also page 59 Fig 19 Ramp function with set point change Set point process value X w A we wp upper set point limit W100 SEE PONE Wie as ee ate okt re tae ita ne AA e g Wp i effectiv set point om process value SEEPOINER E A AA e g W lower set point limit WO gt Time Controller on Switch over Set point 2 gt Set point 1 Tracking Set point tracking gt 106 When switching over between the various set points We and WP undesirable set point steps may occur These steps can be attenuated using the set point tracking function With set point tracking the we wp used so far is stored as internal set point w when switching over from we or wp gt w When switching back w gt we or wp start up is dependent of Grw we or wp setting see Fig 20 The actual controller behaviour process value or set
11. key during gt 3s Para blinks select Hold with up key A and confirm with selection key O see Fig Applications I During optimization frequent access to defined parameters Xp1 Xp2 Tn and Tv is required TT During commissioning limit value LimH1 LimH2 or measurement value corrections must be changed frequently TT With the parameter level disabled access to the selected parameters is possible for the operator Deleting a parameter from the extended operating level must be done at this level see Fig 4 78 117 User manual KS92 94 Parameters Fig 79 Survey of parameters KS92 94
12. o TStart lt TStop lt actual time The programmer is started the stop marker does not switch Switch over functions w W2 and y Y2 and controller output switch off are activated during approx 1s with these functions configured Entry of times and timers Adjustment is sequentially via the front panel time in the system menu timer at parameter setting level or via serial interface saved in EEPROM Adjustment can be started at any step so that year and month day can be skipped The entry sequence must be continued after starting Cancelation is not possible The values are displayed in display 2 e Jet step year 370 e 2nd step month day A e 3rdstep hour minute UHD The time is capacitor buffered separate from the RAM buffer for approx 2 days With memory loss LT 1ckF is displayed in Text 1 91 User manual KS92 94 Timer User manual KS92 94 92 12 07 2000 User defined texts User defined texts 15 1 15 2 12 07 2000 Texti With configuration LEO 1 LU i 99 a free text of 5 characters all displayable 7 bit ASCII characters can be entered via the engineering tool or via the serial interface and displayed in Text 1 Text2 Up to 12 free texts of 16 characters each all displayable characters from 7 bit ASCII can be entered with the engineering tool or via the serial interface and displayed alternately in Text 2 and on the continuous display The display in Text 2 can
13. switch over controlled by Weff switch over controlled by Xeff switch over controlled by Ypid switch over controlled by X W 0DF Decimals for OCnter 0 no decimal point 1 1 digit behind the decimal point 2 2 digits behind the decimal point 3 3 digits behind the decimal point 16 10 DISP User interface for operation Configuration of display function signification via front panel L1 process operation List To LEG Signification of display text2 0 Y correcting variable display bargraph 100 0 100 1 Xw control deviation bargraph 10 0 10 span Ro User text selection no user text user text via control input user text via Front LED function Lanau Language selection of text displays 0 German 1 English 2 French i 0 logic output levels Y1 Y2 LIM1 LIM2 2 Tprog bargrap h elapsed function 1 logic output levels LIM1 LIM4 program time 0 tmax statuses 3 S displ 2 programmer control outputs D1 D4 AS display 3 logic output levels LIM1 Y1 Y2 LIM2 4 PROFIBUS DP errors 5 logic output levels Y2 Y1 LIM1 LIM2 6 logic output levels LIM1 Y2 Y1 LIM2 Unit display L Unit xDisP Disr Unit selection for text 1 select process value for disp select set point for disp 00 no unit 06 t h 0 Process value xeff 0 set point disp Standard 01 C 07 m3 h
14. 125 E Versions fot LL Mo o ba ne gt V kW N User manual KS92 94 Versions 18 2 Industrial controller KS94 of ol7 EEREN KS 94 KS 94 with two wire power supply 90 250 VAC 4 relays OUT1 OUT2 OUT4 OUTS 90 250 VAC 3 relays current logic output POWER SUPPLY AND OUT1 OUT2 OUT4 OUTS PROCESS OUTPUTS 24 V UC 4 relays OUT1 OUT2 OUT4 OUTS Lui N G a de Lui 24 V UC 3 relays current logic output OUT1 OUT2 OUT4 OUTS no interface TTL interface 5 control inputs di3 di7 and 4 control outputs dol do4 RS422 5 control inputs di3 di7 OPTION B 4 control outputs dol do4 and Clock PROFIBUS DP 5 control inputs di3 di7 3 and 4 control outputs dol do4 INTERBUS 5 control inputs di3 di7 4 and 4 control outputs dol do4 m N no extension 2 additional inputs INP3 INP4 1 additional output OUT3 5 control inputs di8 di12 and 2 control outputs do5 do6 1 additional output OUT3 5 no additional function m OPTION C ADDITIONAL FUNCTIONS measured value correction N measured value correction and programmer standard setting 2 point controller 3 point stepping controller continuous controller current logic output reqired PRECONFIGURATION 3 point controller logic relay current logic output reqired 3 point stepping controller as 3 element
15. 19 User manual KS92 94 Operation 4 3 Menus 1 3 Apart from the parameter and configuration words the following dialogue words are used Textl 4 4 User manual KS92 94 Textl Signification CBus CFrnt PC communication via interface at terminals B12 B16 Clear The additional display selected at operating level is deleted gt Mark Clock Setting the clock Cont Transition to configuration level End Return to the previous selection menu Exit Return to operating level main display Hold The displayed parameter is determined as standard display Mark The displayed parameter is stored as additional display at operating level gt Clear Hore The configuration level area described with MORE is accessible OS tar Stor Self tuning is started or stopped Fara Transition to parameter level PEun PStor Programmer starting or stopping Poet Prez Programmer preset or reset uit Return to operating level main display without storage of the values changed last The operating level The operating level comprises main display and extension During the main display automatic or manual operation can be selected With automatic the set point and with manual the correcting value can be adjusted directly AIST In the extension the number and sequence of displays is dependent of selected functions Max 12 parameters from the parameter level can be displayed Mark o Clear S
16. 9999 s Tul derivative action time 0 9999 s Ti cycle time 1 0 4 999 9 s TZ cycle time 2 0 4 999 9 s User manual KS92 94 68 12 07 2000 Optimizing the controller 11 24 A Y off The principle is identical with the control behaviour of a signal function with additional contact Output OUT2 is used for switching over between A and Y Output OUT1 switches the heating power on and off na We Wert WIG 106 Fig 53 ge Static operating Hert principle of the 100 Y off function Y1 Ova 0 L tz zs Medize LU gt Configuration Effective controller parameters C100 EF uri 06 Y off function Lh trigger point separation of additional contact 999 9999 sd signaller switching difference 0 1 999 9 We additional correcting variable 105 105 Ymir min correcting variable limiting 105 105 Ymax max correcting variable limiting 105 105 Fl proportional band 0 1 999 9 Tril integral action time 0 9999 s Tul derivative action time 0 9999 s Ti cycle time 1 0 4 999 9 s 12 07 2000 69 User manual KS92 94 Optimizing the controller 11 2 5 Three point stepping controller In order to match the adjusted Xp to the motor actuator travel time the travel time T must be adjusted The smallest positioning step of the controller is 80ms Dependent of configuration
17. Connection is possible in two or three wire circuit Measuring leads must be of copper The input circuit monitor responds with 130 C sensor break or lead break The output action is configurable for e upscale set point lt lt process value gt 285 e downscale set point gt gt process value gt 2 5 e a fixed value in case of error the selected number is used for the value to be measured gt 13 1 E i EN i 16 15 4 12 i Q Resistance thermometer in 2 wire connection 13 For lead resistance adjustment disconnect the measuring leads CRT 14 i from the controller and short circuit them in the connecting da head of the resistance thermometer Now measure the Ru RL2 resistance of the measuring lead using a resistance bridge and a 0 connect a calibrating resistor Ra of the same value A i 16 15 14 12 i U Resistance thermometer in 3 wire connection 13 i 3 14 Se The resistance of each input lead must not exceed 30 2 Lead 15 resistance adjustment is not necessary provided that the i WY resistances Ra of the input leads are equal If necessary they T TE 16 N must be equalized using a calibrating resistor T Sg A 12 U Temperature difference 2 x Pt100 i RE 1 15 de Range 0 0 is within 200 0 300 0 C 02 referene 6
18. When starting the optimization with a three point stepping controller the correcting variable is always reduced completely and Yort m is output if the instantaneously effective correcting variable yp cannot be measured N 1 I 1 1 1 1 1 For keeping the process within safe limits the set point is monitored continuously for out of limits Whilst self tuning is running the override control function is switched off I e Ypid is within the limits for Ymin and Ymax With controllers self tuning is withfunction 1 e Y2 0 75 User manual KS92 94 Optimizing the controller 12 1 7 Signification of self tuning messages 45611562 HSol Signification or error cause Possible solution 0 No attempt was made or attempt cancelled by switching over to automatic Cancellation GER Change controller output action Wrong action of correcting variable A Wf 1 does not change towards W x e Y 2 Finished Self tuning was successful reversal point found safe estimation Cancellation A Cancellation The process does not react or reacts ee 3 too slowly change of AX below 1 x during 1 hour a ts Finished EEN Increase set point step or t low reversal point Wipe ES 4 Cancellation x 8 Stimulation insufficient reversal point found unsafe estimation Cancellation Cancellation Increase separation of process value X Optimization cancelled due to exceeded
19. do5 do 6 do 1 do 2 do 3 do4 12 07 2000 5 3 12 07 2000 KS92 94 function survey Galvanic isolation Galvanic isolation is necessary for safety contact safety and for measurement reasons Due to the KS92 94 electronics construction galvanic isolation is standard without extra charge A transformer in the power supply always isolates all inputs and outputs from the supply voltage Data exchange between electronics p c b A and power supply or output p c b P is also galvanically isolated Le positioning output OUT1 which can be designed for 0 4 20 mA is also isolated from all inputs Control inputs di control outputs do and serial interface are always galvanically isolated via opto couplers i e they cannot contribute to stray potential and error due to leakage current Although additional current inputs INP3 and INP4 of option C are galvanically connected difference inputs COMMON they are isolated from the rest of the instrument This also applies to current output OUT3 This means if hardware option C is used process value set point and correcting variable can be galvanically isolated Even an additional process value output OUT3 0 4 20mA is galvanically isolated from the input Common control signals as A M w W2 int ext etc e g signals coming from a PLC and in many cases without galvanic isolation are handled with galvanic
20. eos OK ER ee SSS 129 A ey ee en Gb ea a ev EE E 133 General hints General hints 12 07 2000 Industrial controllers KS92 and KS94 belong to a new generation of microcomputer based controllers in the upper performance class Despite their versatility these controllers are easy to operate Not only slow thermal processes but also pressure and flow with short reaction times can be controlled without problems Due to measuring and control functions configurable within wide limits the controllers can be used for a wide range of application Safe reliable control within close tolerances and high plant availability are pre requisites for economic production Controllers with reliable and robust control algorithms are the basis for stable process conditions also with varying operating parameterses A self tuning function ensures short start up times The thinking operator guidance system with standard symbols plain language texts plus software and hardware interlocks prevent operating errors and thus reduce downtimes Controllers KS92 and KS94 are configurable as signallers 2 point 3 point 3 point stepping and continuous controllers Moreover the output functions can be configured for A Y off position control split range control and numerous 3 point combinations of switching continuous control Control modes are set point set point cascade and programmer each with the possibility of set point offset The effect of of
21. gt x1 100 kg h final product 12 07 2000 51 User manual KS92 94 Process value calculation 7 3 Three element control With three element control process value calculation is according to equation x xl a x2 x3 Para gt InPut gt Istll a A A whereby term x2 x3 is the difference between the steam and water flow rates Factor b for flow range matching used so far is omitted because the mA signals are directly converted into physical units during input value processing xo X100 Main variable x1 level is displayed on the process value display however switch over to calculated process value x is possible at the extended operating level start up and set up For selecting a three element controller the Ek YP 2 inf 08 must be entered Fig 29 Example for three element control flow x3 gt INP4 gt steam T A inde e ented E EEEN Fig 30 Block diagram for three element control extended operating level Process value display irr weff au ren tau B___ 60 Display of material flow rates x1 gt a x2 x3 x X1 a x2 x3 x2 DO INP 4 x3 water A mass balance 74 Mean value For controlling a process purposefully the correct process value for the product must be used When measuring e g the temperatures at two different points in a furnace mean value formation can be used for proce
22. 3 pnt stepping w dW dil2 Tracking Outputs OUTI Y1 Y1 OUT2 Y2 Yl Y2 OUT3 Xeff OUT4 Alarm1 Y2 Alarm1 OUTS Alarm2 dol Programmer output 1 do2 Programmer output 2 do3 Programmer output 3 do4 Programmer output 4 do5 Auto Man do6 W Wext 127 User manual KS92 94 Versions User manual KS92 94 128 12 07 2000 Terminology explanation Terminology explanation 12 07 2000 Anti Reset Wind Up A measure which prevents the controller integrator from going into saturation Working pointY0 See section from page The working point of a P or PD controller indicates the correcting variable output to the process with process value set point Although this value is only important for P and PD controllers it may be of interest also with controllers with integrator automatic working point Automatic operation See section from page Normal controller operation The controller uses the adjusted control parameters for process control Automatic operation is effective after switching to automatic operation dil di2 via a digital input AND selecting automatic operation via front panel key Contrary manual operation Bandwidth control See section from page With program control or gradient control there may be quite important control deviations due to the process inertia To prevent these deviations the control deviation is monitored in order not to exceed a preset tolerance band As soon as the
23. 65 User manual KS92 94 Optimizing the controller 11 2 1 Signallers This configuration can be used for processes with small Ty and slow Vmax Control oscillations are determined by T X x En ae Ti X max max u D The signal function corresponds to limit signalling whereby the set point is the limit value The trigger point is symmetrical on both sides of the set point hysteresis Xsq is adjustable The signaller with two outputs has an additional pre trigger point The separation between this point and the set point is adjustable using parameter LW including polarity mE Wi Werf Wise viop Fig 50 Static operating principle of signal function As no manual function is possible with a signaller calibration resistance transducer is only possible by configuration changing e g for two point controller Configuration Effective controller parameters LIDD CFur 00 signaller with 1 output Sgi Signaller switching difference 0 1 999 9 01 signaller with 2 outputs LN Trigger point separation of additional contact 999 9999 ned Switching difference of additional contact 0 1 999 9 User manual KS92 94 66 12 07 2000 Optimizing the controller 11 2 2 Two point controller 12 07 2000 Cycle time T must be adjusted at configuration level It corresponds to the minimum cycle time with 50 duty cycle For optimizing according to the control re
24. dil gt di2 Peto di2 Es i di12 EZ Ey JE amp gt 1 Timer D gt gt W100 gt E El Grw2 y ae gt WSel p AN INP3 gt A A ww x w gt W2 6 4 Safe set point W2 Second set point W2 can always be activated with highest priority In the past W2 was called safe set point Whether W2 can have safety functions or whether it is only a pre defined start position in defined process conditions is determined only by the way it is used and integrated into an automation concept Dependent of configuration switch over to set point W2 is possible via interface front operation timer or one of control inputs dil di2 or dil2 XL 917 Second set point W2 is handled with priority If W2 was selected anywhere front panel interface or the relevant control input switching over at another facility is not possible 6 5 External set point Wext Dependent of configuration switching over between internal and external set point via interface front panel operation or one of control inputs dil or di2 is possible XL 97 For making the external set point effective a 1 signal 24 V must be connected on the int ext contact For activating the internal set point a 0 signal OV must be applied to the int ext contact Analog input Wext is connected to INP5 however it can be configured also for IN
25. t 3 GPL PD the feedback can be switched off Adjusting the neutral zone The neutral zone Xs can be increased with excessively frequent relay switching Note however that an increased neutral zone will cause a decrease of the control sensitivity Therefore we recommend to optimize switching frequency wear of motor actuator and control sensitivity Ma Wa Wert Wife 100 Fig 54 Static operating principle Heft of the three point 100 100 stepping controller Yo WE Sr a ne 0 Three point stepping controllers can be operated with or without position feedback Yp Yp is not required for operation Fig 54 show the static characteristics of the three point stepping controller with inverse and direct configuration The hysteresis shown in this diagram is practically negligible however it can be calculated from the adjustable min pulse length Tpuise 2 100ms PS ed Tm A sh With Tp ul e switched off the shortest positioning step T pul 5 is dependent of Tm Xsh and Xp By variation of RSH the required min pulse length T Pul 5 can be reached Tpuls m X 12 5 Xp 0 75 Correcting variable limit with three point stepping controllers With 3 point stepping controller with position feedback the output is limited to ymin and ymax Checking if the Yp value is higher than ymax or lower than ymin is done exclusively If this is the case further closing or opening pulses are suppressed Due to th
26. tracking off 5 dil offset off 5 Timer W2 6 di2 offset off 6 dil W 7 dill offset off 7 di2 W 8 dil2 W Allocation of digital signals for the controller functions 5 AM SPI F GM Zon Gott Automatic manual 3 pnt stepping controller feedback off Output of safe Switeh off controller manual switch over otherwise PI P switch over correcting value 0 auto manual via front 0 PI fixed 2 0 Y no Y2 2 0 controller on off via 1 fixed to manual 1 fixed to P action 1 fixed to Y2 front W 2 dil manual 2 dil P action 2 dil Y2 1 controller fixed to off 3 di manual 3 di2 P action 3 di2 Y2 2 dil controller off 4 Backup run 4 dil PI action 4 timer Y2 3 di2 controller off 5 dil auto 5 di PI action 5 dil Y 4 timer controller off 6 di auto 6 di2 Y 5 dil controller on 6 di2 controller on Mi Allocation of digital signals for the programmer he A UR only with programmer configured H Dn H More Coni Ine alltc SEESE Signal source for programmer run stop 0 Run Stop Front 1 Run Stop di4 2 Run Stop di4 and timer 1 1 With programmer configured switch over is between internal and program set point 2 Selectable via interfaces e g engineering tool operating data User manual KS92 94 102 12 07 2000 Configuration 16 6 INPUT 16 6 1 12 07 2000 The signal inputs for the previously sele
27. 0 0 999 9 0 hl Neutral zone Xw lt 0 0 0 999 9 0 meh Neutral zone 0 2 999 9 0 2 Set H Parameter set 0 Fl 8 Proportional band 1 0 1 999 9 100 ARE El Proportional band 2 0 1 999 9 100 Tri amp Integral action time 0 9999 s 10 Tui pg Derivative action time 0 9999 s 10 Ti BH Duty cycle 1 0 4 999 9 s T2 amp Duty cycle 2 0 4 999 9 s Seti Parameter set 1 Fl 1 Proportional band 1 0 1 999 9 100 ARE Proportional band 2 0 1 999 9 100 Tri 1 Integral action time 0 9999 s 10 Tud 1 Derivative action time 0 9999 s 10 Ti 1 Duty cycle 1 0 4 999 9 s Tz 1 Duty cycle 2 0 4 999 9 s Set2 Parameter set 2 Fl OZ Proportional band 1 0 1 999 9 100 SPZ OZ Proportional band 2 0 1 999 9 100 Tal 2 Integral action time 0 9999 s 10 Tui 2 Derivative action time 0 9999 s 10 Ti Duty cycle 1 0 4 999 9 s Tz Duty cycle 2 0 4 999 9 s Sets Parameter set 3 ARI A Proportional band 1 0 1 999 9 100 SPZ A Proportional band 2 0 1 999 9 100 Trl 3 Integral action time 0 9999 s 10 Tui A Derivative action time 0 9999 s 10 Ti A Duty cycle 1 0 4 999 9 s Tz A Duty cycle 2 0 4 999 9 s Recon Rapid Recovery controller on Flle X W limit value X W lt Klor Y tracking 0 9999 Ze SANTIN TS X W limit value X W gt Won X tracking 0 9999 Drun set point gradient with X tracking active 0 01 99 99 min Des Decimal point p
28. 54 SA Override Controls kee EA eee e La aS dar 54 8 4 1 Override control with continuous output 64 2c kee 0 4 a eR EC 54 8 4 2 Override control with three point stepping output 54 8 5 Bumpless A M switch over arnes ad a HERE KEE RRS A e HES 55 8 6 Motor actuator output action zur Harrer nie 33 8 7 Positioning output switch off 3 4 zo a aha na a a ne an cken 56 8 8 Controller output action with sensor break e 56 8 9 Position feedback YP se a u ac en Ee sa RR A E 56 ES Special Functions s ere e Ae ea ars A 57 9 1 Control using a disturbance signal osorno RE RS A 57 9 1 1 i SIM Als ERAS we ew ROR a ee E 57 9 2 Rapid RECOVERY AA 39 9 201 Y Storad eee se abe bee eo ee we ee ee A ew ee ee 59 9 22 Set point ramp after switch on excursiones A E 59 9 3 DAC Actuator monitoring lt 4 lt 6 Ka se RR RR OR ooh DED RR WE ES 60 Alarm processing o e sec AAA AAA 63 10 1 Alarm Ll ari a a oe BO ni 64 10 2 Alarm 2 imit Zoe au ak Bas ra AAA ARA A 64 10 3 Alarm EE AEN E ek CEET 64 10 4 Alarm 4 limit 4 4 2 owe 8 oe eee a rare EE BS 64 Optimizing the controller lt Hs su HH 0 ann 65 11 1 Progess charasleristicee s sis ea se BE Ge we oe er E we OR 65 11 2 Controller characteristics o ers ce os di Sk ee Re a de da 65 Eer Senales ca ek A nr Blas Bae eo ewig e ba 66 1122 Twe poimt conmuller 5445462455 a a bah reg 67 11 2 3 Three point controller s oo a u Da Ge EE 68 in AJY Ole ges 6 6 4 ee
29. D di 2 ge 5 ECE lt SE 4 Volt GIS pE E OUTS E 5 5 mA El 6 S u 6 a INPS Es Ef SEE vi ARA d H 1 100 16 16 o z Ve E Lim e Du TE T IN vi ii 9 1 0 9 i 10 1 SE 2 H L 7 our f3 on SG D f i f a Volt gated oe iE E Moe oe NP QUT 7 ua Hr gt hi yo 7 ee ate I ae O En OS en a b c d e f iC B e MEE TI a K S is A 9 i i 3 q T 9 i 3 en e 13 fani 6 i di 5 di heal 7 di 6 0 8 i di 7 gt do 6 9 E i _ GND 10 do 2 INP4 Ian za i GE 15 8 2 o INP3 Ian zu BCE Ee R GND ND GND i URXD A TRE RxD TxD N DUES KEN MOS JAME TKO namen 11 E ulXD A DATAA RXD RS422 RS485 rm PROFIBUS Versions with integrated supply voltage connection example look at page 13 User manual KS92 94 Electrical connections 3 1 3 2 XI X2 X3 X2 Supply voltage connection The following controller versions are available AC versions e 90 260 V AC KS92 only 230 V AC Frequency 48 62 Hz Power consumption approx 10 VA 24 V UC versions only KS 94 e 24V AC 48 62 Hz The voltage limits are 24 V AC 10 15 e 24VDC With the 24 V DC version the limits are within 19 2 and 30V Connecting the analog inputs INP Input INP1 Q Input for variable x1 see page 31 ff a Thermocouple b Resistance thermometer PT100 in 3 wire connection c Temperature difference a
30. If self tuning is finished with an error AGS_F the stable correcting variable is output until self tuning is C finished by the user via the system menu front panel key or via the interface User manual KS92 94 74 12 07 2000 12 1 5 12 1 6 gt Be ee 12 07 2000 Optimizing the controller Self tuning procedure with heating 2 point 3 point stepping continuous controller After reaching process at rest the process is started with a correcting variable step and Tul and Vmax are determined from the process reaction if possible at the reversal point of the step response Self tuning procedure with heating and cooling processes 3 point split range operation Self tuning starts as with a heating process After the self tuning end the controller is determined from the calculated parameters These parameters are used for lining out to the pre defined set point until PiR is reached again For determining the cooling parameters a set point step is output in order to determine Tu2 and Vmax2 using the step response Based on these parameters the parameters for split range operation are also determined for cooling When cancelling the cooling attempt the parameters for heating are also used for cooling Error AdS_ F signalling is omitted Fig 61 VOrtm det adaption optimization optimization start heating cooling finished finished
31. Set point process value effective set point Final set point GruDr not active correcting variable Bm is Ne al Y tracking Y mere X tracking TES Controller signal standby controlling outputs switched off storage j i i a YPID Xeff Wfinal don t store storing Y storage For this the controller continuously stores data on the actual working point correcting variable control variable target set point in the capacitor buffered RAM which even provides back up with mains failure of more than 6 hours After mains failure or plant trouble safe data on the working point are available These data will be used by the controller to return to the working point sooner After power failure or plant disturbance the controller goes to the correcting variable of the old working point automatically and starts controlling at the correcting variable This is of particular advantage especially with three point stepping controllers This function will show good results if the interruption was short As the term short must be considered in relation to the process time behaviour however the change of process value and set point up to which Y calibration is required after power failure can be adjusted via the parameters This is done using new parameter XwOnY With three point stepping controller without position feedback and signallers this function is not provided
32. Text 1 indicates the short form dialogue or the unit of display 2 Further displays can be adjusted by means of configuration code L A HH Text 2 indicates the correcting variable bargraph Further displays can be adjusted nr by means of configuration code C A DH PC interface PC connection for configuration parameter setting and operation by means of the engineering tool Status displays This message signals a sensor error Possible cause Break or wrong polarity with thermocouple m Break or short circuit with Pt100 and potentiometric transducer Break with 4 20mA and 2 10V standard signal Faulty clock real time clock must be re adjusted Recovery function is active after power recovery the process is controlled with the correcting variable determined last Gradient function is active the set point changes at an adjustable Grw rate of change The second correcting variable safety correcting variable is active Self tuning was canceled with error Self tuning busy Timer function is active a future starting point was not reached yet Calibration error with automatic position feedback calibration No motor actuator reaction only with the DAC function activated Faulty motor actuator output action only with the DAC function activated Yp error potentiometer defective or not connected only with activated DAC function
33. and L are adjustable in the set point parameters Current set point ramps Grw Grw are stopped when leaving the band 12 07 2000 85 User manual KS92 94 Programmer 13 4 13 5 Manual programmer operation The function of front panel key A M lt was already defined for controller operation adjustable in the parameters FKe 4 The adjustment range of this parameter contains the following points key without function lo e Automatic manual e Wp W wext wint Key switches the programmer to internal set point W adjustable with the arrow keys and back In this case key is used for internal external switch over whereby the programmer continues running in the background for the duration of manual operation In the programmer reset position key lt switches over between Wp0 gt W Run gt W switch over is bumpless with the controller configured for tracking storage of We or Wp as internal set point W E 0A and E 92 After switching back from manual W gt Run the programmer starts from the instantaneous process value and searches the end value of the segment with gradient Wpi Wpi 1 Tpi active when switching back search mode Search mode E 20 Purur Search mode is started automatically after mains recovery if the program was in run mode before mains failure and with search mode configured 20 PULP Within the presently active segment the program
34. t 1 t E oad 4 co AH Co Au LO value pair 6 value pair 7 L Ca Li Eu x value pair 8 The range for these configuration words is within 999 and 9999 or switched off 16 7 4 Signal output 4 OUT4 Used for configuring the source of output OUT4 This signal output can be configured for extensive functions Main configuration ID Src Tare Mode Signal source Output stage Actuator output action 00 output switched off 28 alarm 4 limit4 0 relay switching 0 not selectable 01 controller output Y1 Youtl 29 programmer output 1 1 direct normally open 02 controller output Y2 Yout2 30 programmer output 2 2 inverse normally 25 alarm 1 mi 31 programmer output 3 closed 26 alarm 2 limit2 32 programmer output 4 27 alarm 3 limit3 33 program end 16 7 5 ignal output 5 OUTS Used for configuring the source of output OUT1 This signal output can be configured for extensive functions Main configuration Main Sre Tyre Mode Signal source Output stage Actuator output action 00 output switched off 28 alarm 4 limit4 0 relay switching 0 not selectable 01 controller output Y1 Youtl 29 programmer output 1 1 direct normally open 02 controller output Y2 Yout2 30 programmer output 2 2 inverse normally 25 alarm 1 mi 31 programmer output 3 closed 26 alarm 2 limit2 32 programmer output 4 27 alarm 3 limit3 33 p
35. 05 3 pnt controller heating switching and cooling continuous 06 A Y off 07 3 pnt stepping 08 3 pnt stepping with Yp INP6 09 continuous with position controler 10 continuous 11 continuous split range only with Optin C OUT1 and OUT3 12 continuous with current feedback via Yp INP6 Coupe Controller type 0 standard controller ratio controller oC 187 3 element controller Xeff x1 a x2 x3 mean value Xeff 1 b e x1 b x2 WFuric Set point function 0 set point 1 set point cascade 2 programmer 3 set point with ext offset 4 set point cascade with internal offset 5 set point cascade with external offset 6 programmer with internal offset 7 programmer with external offset Main controller configuration 2 Cbiff Differentiation 0 differentiate Xw 1 differentiate X Output action 0 inverse neutral 1 direct hu NN Oo lt CFail controller outputs switched off Ypid Ymin 0 Ypid Ymax 100 Ypid Y2 adjustment via front panel not possible Ypid Y2 adjustment via front panel possible Controller behaviour with main variable sensor break 99 User manual KS92 94 Configuration More More More More More Use of an auxiliary variable and external y limiting Lux COU Auxiliary variable z via INP3 6 Output limitin well no 0 Yo
36. 6 LA With program control with internal offset the set point is determined by internal programmer Wp The programmer value can be affected by an internal offset dW The KE set point offset type additive or factor is determined during x configuration E WE by parameter dl The offset is switched on via signal source Shar determined in configuration parameter i 190 The resulting set point or internal set point W can be selected Switching over is done via signal source Sli e determined in configuration parameter E 41 Ww U Programmer with external offset WFunc 7 EN NER Aer With program control with external offset the set point is determined dWon es by internal programmer Wp dwe NPs N lt Jww2 The programmer value can be affected by an external offset dW The INP 1 ver type of set point offset additive or factor is determined during S Ee configuration E WE by parameter dl The offset is switched on via signal source Shica determined in configuration parameter 190 This set point can also be affected by an external offset dWe Switching over between the resulting set point and internal set point W is also possible and must be done via signal source Sli determined in configuration parameterl 90 User manual KS92 94 42 12 07 2000 Set point functions 6 3 Detailed set point function block diagrams The following set point function block diagrams illustrate the interactions of co
37. 83 13 1 Control signals and status messages 84 1341 10 Pesstequisites sss pean Cs Sew Gack eRe ae GP ea a ee eS 84 13 2 Changes in the program sequence ze rres can Ge eS Hee Ae ae A 85 13 3 Bandwidth monitor spee sa eas eae Gch we od Se eA ewe SRE De Sus 85 13 4 Manual programmer operation 4 0454 44 9 ds rada ea gay RR EHS 86 13 5 Search mode L Fe Pk AF zu cosa bau da esa ee 86 13 6 Behaviour after mains recovery and after removal of sensor errors 87 13 6 1 Memory loss RAM aws bedoe Hau ana Par ara 87 13 6 2 Memory RAM available 444 as 4a Km ya ya a BOS SH ne 87 VI Preset eee adie oe ee ae eee Bee AAA a 87 13 8 Sensor atl cs sa AE a OS LO AG a Fr air ale 87 13 9 Programmer displays sece sose Hoe ed t ra Oe SH PER AS A 88 13 941 DSPACE ORE ARS wre 88 139 2 Display 2 se oi BR ee a re ERM HE EOE ee od we E 88 13 93 ERE e oe eo oe ASADA RIA 88 139A MC o ee Gea EL ee ee EE we a Wera 88 13 10 Prosrtammier Opet tion ssoi s pira s Be a Boe FER BGR PGE ee OHS OD E 89 13 11 Inputs and outputs parameters configuration sa va ana are 89 qe eset eee eee ae oe be a eee euere 91 Bl DO ong gow oo A 91 142 Entry of times and timers a RAR AR RA A AA 91 User defined texts e en aedi a iaa o A A 93 A Tel as ercer das rr EE Os 93 ERA AA II II 93 Configura ARANA RA A A RS 95 KO LEGE ER EET ERS ESS ee EERE SEO Ee Poe ESS 95 16 2 Basie structure i a ax 3 are 5 wee Roe GR EE AS a ER ER ers 95 16 3 Main sfoups ye 4
38. A Ge ee ea wae Dk oe eee oe 41 Detailed set point function block diagrams o oo 43 Safe set point VW 2 sra dc Es A eee Boe AA a A 45 External set point Wer E EA DAA 45 Setpoint Olisel aia 2 45 8 44 ET RE e ur 46 EBumplesSness A 6 2 2 as ara aras AR 46 6 7 1 Set pont changes se iwi rara ii EA EE a 46 6 7 2 Set point switch over w w2 Wext Wint w wp Controller On 47 TACO teaa na s ao a e RE A See a ee Se So dl A 47 6 8 1 Set point tracking gt IHE iaa a a a ca ch 47 6 8 2 Process value EUR a au 0 ow A Se Maw Rew Ree AS 48 6 8 3 MIN MAX selection WSEl 2 oa 6 S60 ce eR tod EEA H EEG Ho 48 Process value calculation l ee 49 Til Standard controller 2 646 444 08408 da Sk Ba a Hes 49 12 Rallo Controller s ss e a er ee ee a OYE EEE WE ee eR oe 49 72 1 Conventional ratio Controls sa 4 4 saw 66 cheb a 49 7 2 2 Additional possibilities of ratio control with KS92 94 49 7 2 3 Example for standard ratio control 26 445263 6424 sa sr ar aa 50 7 2 4 Material batching and mixing es 44 444 G34 ev eee d oe ES 50 To Three element Control seos s e a a ee eed AR BS ee 52 TA Mean EE gr de ee e e e e E SES EGS 52 Sq Correcting variable processing we NEE EE noes 53 8 1 Second correcting value au u han a SAE ER Oe Sw HOH er a BS 53 8 2 Correcting variable limits run ec dr OREO GARA 53 8 3 External correcting variable limiting override control
39. Display of configuration data without modification During remote operation the PC interface cannot be operated When switching over from LOCAL to REMOTE an active PC interface is switched off PROFIBUS interface During LOCAL only reading of all data via the serial interface is permissible front panel interface Modifications are not possible exception any data related only to the interface or which are not adjustable local via local operation front panel operation R L input 17 User manual KS92 94 Electrical connections 3 7 3 Connection examples Fig 1 TTL interface connection Interface module AA I ZE max 1m ho 2 SEN EE SR 13 AND Pee A hi 14 RE FA ALE 4 mp ee AS _ us RXD is Sa A O Fig Master e g 1 OT150 max 1000m RXD B GND RKEDEA A E EE ENDRES TXD A 33 sb oe se ea 4 RS485 interface connection Fig 3 PROFIBUS DP connection OA 12 VP 13 GND max 1200m 14 jf H RXD TXD N A e a 15 RXD TXD P AB a ic engen A 16 Fig 3 INTERBUS connection DN BO ODO Ch E DO i
40. Fig 44 Yp signal pressure DO bar als un ae aes i eg cig 5 18 5 bar gt en de o c PN 18 bar gt so LE SS E V 17 5 bar gt Set point offset Yp 0 bar 0 no load h0 50 100 full load Fig 45 Block diagram for Yp signal 127 tou INP1 4 cm 150 inputi input Vin ep A A AA Calibration Signal pre processing User manual KS92 94 58 12 07 2000 9 2 9 21 9 2 2 Special Functions Rapid Recovery After short term mains failure or plant trouble the process might have deviated from its working point only minimally With controller start without previous knowledge the working point will be redetermined by evaluating the control deviation As the control deviation might be very small this will take rather a long time i e there will be a drop If the controller knows its old working point start is possible using the right correcting variable for this working point i e the working point will be reached again much earlier This is ensured by the Rapid Recovery function which is divided into two independent functions Function Y storage and Y tracking ensures the approach to the correcting variable required for the working point With higher deviations of the control variable from the target set point function X tracking ensures smooth set point line out to the target set point starting from the actual control variable
41. Ono bm ODOT 11121 GODOT Sa E DO ee Gei 3 DI 2 grey a Ge pl 3 DI ae e S d GND 3 brown Se LV ed al DI 2 9 voy D 577 linked 1 ve 8 GND 3 brown i a 9 I L elle Ni a i 1 a Strain _______ d Strain ege t i a relief relief a receiving interface User manual KS92 94 18 sending interface 12 07 2000 Operation A Operation 4 1 Front view 4 2 12 07 2000 Fig 6 Front view LED3 e g Alarm 1 LED2 e g Cooling LED 1 e g Heating ee LED 4 e g Alarm 2 Locking screw wl ri wl wl Display 1 e g Process value Text e g physical unit WW pp op Display 2 e g Set point Text 2 e g Bargraph a Dialogue Y BERGE aoe Selection key PC interface E O Increment key 1 Manual Automatic key __ Decrement key 1 Locking screw Locks the controller module in the housing LEDs indicate the status of controller outputs Y1 Y2 and alarms LIMI LIM2 other settings at configuration level LA HH Display 1 indicates the process value at operating and parameter level and the configuration code at configuration level Display 2 indicates the set point during automatic operation at operating level and the correcting value during manual operation The values are adjustable directly with push buttons v and 4 Further displays can be adjusted by means of configuration code HD 1
42. Parameter Range Default sworn 0 9999 function switched off Y calibration is done with x lt XwOnY and w lt XwOnY Set point ramp after switch on The second rapid recovery sub function is the set point ramp If the process value still deviates from the set point by a value exceeding the adjustable parameter Mw Oi after controller enabling according to configuration E 13 1 5faFF On gt see page 102 control to the set point is via parameter GrwOn Parameter Range Default AWOKE 0 9999 function switched off Grwon 0 9999 77 function switched off IS A set point ramp is activated when xw gt XwOnX 12 07 2000 59 User manual KS92 94 Special Functions 93 DACH Actuator monitoring DACO ensures operating safety Digital Actor Control monitors the actuator safety and detects problems before there would be an increased control deviation Monitoring is done for blockage defective motor or capacitor or for other actuator problems affecting its function The DAC function is available for three point stepping controllers with position feedback continuous controllers with position control and continuous controllers with position feedback U Introduction With all controller types featuring position feedback Yp the motor actuator can be monitored for functional troubles With these controllers Cfunc 08 09 12 the actuator function is monitored completely Monit
43. Square root extraction gain 0 9 999 1 TES Filter filter time constant 0 999 9 s 0 5 Signal processing for INP6 re Scaling gradient m 0 9 999 1 b Scaling offset b 999 9999 0 SairiG Square root extraction gain 0 9 999 1 TRE Filter filter time constant 0 999 9 s 0 5 User manual KS92 94 122 12 07 2000 Parameters 17 9 Miscellaneous Text Description Range Def Hux General Fkes Function of front panel key E 0 no function 1 automatic manual 1 2 Wext Wint Elck1 EEloc extended operating level 0 free l blocked 2 blocked by dil 3 blocked by di2 0 HE IOC auto man key 0 free 1 blocked 2 blocked by dil 3 blocked by di2 0 CB lac controller off 0 free l blocked 2 blocked by dil 3 blocked by di2 0 WE IOC setpoint 0 free 1 blocked 12 blocked by dil 3 blocked by di2 0 Elckz FEloc programmer preset 0 free 1 blocked 2 blocked by dil 3 blocked by di2 0 FE 1c programmer run stop reset 0 free 1 blocked 2 blocked by dil 3 blocked by di2 0 DE loc selftuning 0 free l blocked 2 blocked by dil 3 blocked by di2 0 17 10 Signals Signl Description Range Def ELFT Setpoint signals Wirt Internal set point ext External set point Alle t External correction hl Set point offset 99 9 999 9 0 Heel Min max set point OALE Controller signals Correcting v
44. Tu _ Vmax K Tu 100 Controller characteristics The control parameters can be determined from the values calculated for delay time Tu max rate of increase vmax control range Xh and characteristic value K according to the formulas given below Precise adjustment should be done as specified in the table Increase Xp if line out to the set point oscillates General formulas Reference values Behavior Xp Tv s Tn s Parameter Control Disturbance Start up behaviour D PID 1 7K 2 Tu 2 Tu Xp bigger stronger damping slower line out slower reduction of duty cycle PD 0 5K Tu joo 0000 smaller reduced damping faster line out faster reduction of duty cycle PI 2 6K 0 6 Tu Tv bigger reduced damping stronger reaction earlier reduction of duty cycle P K 0 co 0000 smaller stronger damping weaker reaction later reduction of duty cycle 3 point stepping controller PID Tn bigger stronger damping slower line out slower reduction of duty cycle 1 7K Tu 2 Tu smaller reduced damping faster line out slower reduction of duty cycle The various control functions are adjustable with configuration parameter 80 CF unc Direct inverse switch over is always possible according to configuration D 1 CMade The principle is shown in Fig 49 Fig 49 Direct inverse switch over principle invers direkt V W Xd w x Ir OUT1 x gt OUT2
45. With display overflow gt 99 hours only the full hours are displayed The minute display is omitted HE Text 1 At operating level the selected unit is displayed in Textl At extended operating level the following displays relevant for the programmer can be selected A V e program time THet Extended operating level without pause times BH Exit et e program time TEr ut incl all pause times e rest time Rest e recipe number PHr e controller status State Text 2 Operating level L Continuous display The continuous display in Text 2 is configurable HDD Text 2 With program controller the elapsed net program time TNetto can be displayed as Bargraph 0 100 The dark part of the bargraph represents the rest time Test which is displayed right beside the bargraph For Test lt 100 hours the rest time is displayed in hours minutes Test gt 99h is displayed in full hours Status indication At extended operating level KS94 text line Text 2 is used as additional status display Text2 contains 16 characters which are classified as follows 7m 7m Luc y y User manual KS92 94 88 Set point Explanations Status Explanations Status Explanations symbol Internal set point sone no bandwidth monitoring and KS94 is in
46. a 14 i 2 R E L 15 i For lead resistance adjustment for INP1 take the controller into Xe 0 n manual operation and select calibrating parameter x Ac as 16 shown in Fig 12 Press the selector key to prepare the e e calibration CG in the display Ec flashes Now short circuit AL 0 v RL2 il the input leads at the two PT100 resistors Press the selector key again to store the measured resistance value as lead resistance 7 t t the subsequent measurements accordingly REN ASA sl User manual KS92 94 32 12 07 2000 12 13 14 15 16 A e l mA A 12 13 14 i Volt 15 16 i 12 07 2000 KS92 94 function survey Potentiometric transducer The overall resistance lt 500 Q incl 2 RL Calibration or scaling are done with the sensor connected An input circuit monitor can be configured for sensor or lead break or short circuit The action process value correction and decimal point are adjustable 30205 andit 13 Configuration is in the following order LEO LOS Ee tt Ed E N Calibration for Xo and X100 is at parameter level as follows Calibration is only possible with the controller set to manual mode Potentiometric transducer calibration for Xo or X100 1s possible via the interface and the front foil Calibration is in two steps Fig 12 Selecting parameter HG x188c
47. action with sensor break can be selected only with 4 20 mA standard signal gt 455 and CHEI For input value processing a filter time constant with a numeric value within 0 5 and 999 9 can be adjusted SEBA Configuration is in the following order HD EM EHSA 455 HEI EHEH See also position feedback yp page 56 Digital inputs di Energization of digital inputs di via an external 24 V DC supply is required The current consumption for each input is 5 mA The digital inputs can be energized by one or several voltage sources e g 24V PLC control outputs Note that the negative potentials of the voltage sources are identical and must be taken to the corresponding controller connecting terminals Connecting examples 24V 24V ext Ia Imax 5 ma di 3 Une 5 mA di 4 Imax 5 mA di 5 Imax 5 mA di 6 Imax 5 mA di 7 Imax 0 1 A Imax 0 1 A Imax 0 1 A 24V ext 2 3 4 5 6 7 8 9 0 1 fo fr foo fo for foo IN Imax 5 mA _ di 1 Imax 5mA di2 1 Digital inputs Digital inputs and outputs at one voltage Digital input and outputs at two voltage connector A source connector B sources connector B Digital inputs dil and di2 Dependent of configuration 130 and E 13 1 digital inputs d1 and d2 can control the following operations Allocating several functions to a digital input is also possible S
48. applications is possible by adjustment of as few configuration words as possible Moreover the structure was designed flexible enough to permit additional configurations also for realization of special applications Basic structure The first menu level permits selection of the main configuration group The user can be guided through all function configurations or he can configure the specific functions required for his application directly For all complex main groups a two level configuration concept which enables the user to select the correct setting for his application by defining only one configuration word was determined If necessary special functions can be determined separately For the normal user however the configuration words are preset to purposeful default values For simplification the hierarchic configuration dialogue is structured so that the user can and must adjust only the required configuration words The user configuration dialogue is started via selector key OU and increment decrement keys a Y like with the other KS92 94 operating levels e Press the selector key to select menu items input values input positions within a level and to change over to the next higher level at the end of a level e Press the increment decrement keys for returning to a lower level and for modification of input
49. be kept separate from all other cables L The protective earth which is to be taken to terminal A11 P13 with continuous controllers must be grounded via a lead which should be as short as possible 15 cm during test L When connecting a contactor to the relay output an RC protective circuit is required to prevent high voltage peaks which might cause trouble to the controller User manual KS92 94 10 12 07 2000 Mounting and connection 2 1 Mounting The mounting position of controllers KS92 and KS94 is uncritical Mounting and connection Sufficient space for mounting should be provided on the rear of the control panel The controller mounting procedure is as follows e Mark and realize the panel cut out as shown in the drawing below e Insert the housing into the panel cut out from the front e Fit a fixing clamp to the controller top so that it locks into one of the housing cut outs Tighten it slightly using a screwdriver e Fit the second fixing clamp accordingly on the controller bottom in diagonal position to the upper fixing clamp e Tighten the two fixing clamps until the housing is seated firmly without distortion For reaching protection type IP65 between controller and panel an additional sealing ring must be provided Moreover two further fixing clamps are required The mounting material required for this purpose can be delivered on request 96 W Ls g2 0 8
50. control commands act on the analog output profile Control outputs are forcibly tracked e Run stop e Preset and preset value program time or segment start e Reset The analog output also determines the displays e status run stop reset preset e program set point e actual segment no o elapsed times net gross program times rest time 79 User manual KS92 94 Programmer 13 1 2 Segment parameter entry The number of segments is generally fixed to 20 for all outputs Whether all or only part of the segments are used is determined only by the entry of segment parameters time value The first segment time 7pi 1 which follows on segment Seg defined last is adjusted with 4 32000 and completes the entry sequence so that the request for entry is completed N Entry of segment times Tp 0 9999 minutes without decimal points Entry sequence per recipe at parameter level display 2 Change mode Umade step ramp Preset mode Frade program time segment start Number of following program FHext End Bandwidth LE a Sian Aus Bandwidth LC Input Contr Reset value WFH analog output Tune Imit Pros Timer Gen alt m a EI m 3 EH U U U O D O O Set point profile e Set points WF 1 WPF ZE e Segment times TF1 TF26 min Reset value DH cont
51. control deviation is out of the tolerance band the set point change is stopped Three element control See section from page Particularly suitable for processes in which load changes would be detected too late e g level control for steam boilers In this case a disturbance variable is used at which the mass balance steam removal feed water is evaluated subtracted and added to the control variable after differentiation if necessary Feed forward control See section from page Particularly suitable for processes with long delay time e g pH control An auxiliary variable is used at which the evaluated differentiated or delayed value of an analog input is added directly to the controller output to avoid the controller time behaviour Gradient control See section from page Particularly suitable for processes which do not tolerate energy shocks or quick set point changes Set point changes are bumpless in both directions because the effective set point always runs towards the changed set point target set point by means of gradient Grw or Grw For the second set point w2 gradient Grw2 is effective in both directions also after switch over w gt w2 Manual operation See section from page When switching over to manual operation the automatic control loop operation is interrupted Transition between automatic manual and vice versa are bumpless Manual operation is effective after switching over to manual via a digital input d
52. control output 1 control output 2 control output 3 control output 4 expired programmer time Outputs run stop eff reset eff program no eff end control output 1 control output 2 control output 3 control output 4 Wp TBrutto TNetto TRest segment no analog segment no digital Analog inputs Process value from controller Set point Wp Manual set point internal set point W of controller Program time Tnet Program selection via front panel interface Program time Tgross 12 07 2000 Rest time TRest Actual segment number Seg a analog output and Seg d control output Final value of actual segment 89 User manual KS92 94 Programmer Control inputs Control outputs Run start stop static end Reset flank e i ext int Failure Fail reset ext int stop run PrNr via digital inputs Preset via operation Parameter Reset value Wp0 segment parameters Wpi Tpi Configuration Source of program selection control inputs front interface source of run stop signal Change mode Wmode step ramp valid for all segments default ramp behaviour after program end Behaviour after mains failure Function of A M key FKey Default display in Text 2 Bandwidth LC Bargraph TNetto 0 100 Bandwidth LC Preset mode Pmode time segment star
53. controller only with additional inputs INP3 INP4 N Aa YN Fa continuous controller as 3 element controller 6 only with additional inputs INP3 INP4 Setting to specification manual reqired 9 User manual KS92 94 126 12 07 2000 18 3 12 07 2000 Input and output allocation with pre configured units The signal e g X1 Y1 alarms allocation to the inputs and outputs for the relevant pre configuration factory setting is given in the following table Allocation can be altered at any time via front panel or interface and should be corrected before commissioning if necessary Versions Order numbers and pre configured instrument functions Il mn ay eS ah 8 FEIN a lus AS cee 22 22 E 433 SE 2 eg ita FE FE BE AER CER SER eil eS sz aL ZEE aes SEES 2382 SE SE Gg 23 aeel xZe eee 882 Fe Fs Fe SEs ee 2 52 528 55 85 82 888 843 88 a S aS aS EA 32 29 EES an Inputs INP1 X1 INP3 X2 X2 INP4 X3 INP5 X2 Wext Wd Wext X2 Wext Wd INP6 Auxiliary variable Z E dil W Wext di2 Auto Man di3 Local Remote di4 Programmer start stop di5 Programmer reset di Program selection Select prg 1 di7 Program selection Select prg 2 di8 Select parameter set 1 di9 Select parameter set 2 dild OVC 3 pnt stepping dill OVC
54. external limiting 01 X Z in conjunction with the process value without differentiation 1 OVC 02 X dZ dt in conjunction with the process value with differentiation in both directions 2 OVC 03 X dZ dt in conjunction with the process value with differentiation and positive change 04 X dZ dt in conjunction with the process value with differentiation and negative change 05 Y Z in conjunction with the correcting variable without differentiation 06 Y dZ dt in conjunction with the correcting variable with differentiation in both directions 07 Y dZ dt in conjunction with the correcting variable with differentiation and positive change 08 Y dZ dt in conjunction with the correcting variable with differentiation and negative change Set point functions only with option C Wext and not with 3 element controller WTrac d H Sel Behaviour of Wint when switching over from Wext to Wint with the w Type of set point MIN MAX selection tracking input switched on tracking 0 Set point tracking 0 additive 0 no selection 1 Process value tracking 1 factor 1 Max selection Weff 2 Min selection Weff Ratio functions only with ratio controller Ratio ADF Ratio control function Process value decimal point 1 x1 NO x2 0 no digit behind decimal point 2 x1 NO x1 x2 1 1 digit behind decimal point 3 x2 x1 NO x2 2 2 digits behind decimal point 3 3 digits b
55. functions sae Sess dage A ank SEK Ge A 113 KOMET COM settal interface se 24 2 ca Br Far eRe Re ee LADE 113 Doll WARIO AEG e a oeio e e eoe AA 113 6 1123 Forcing signal input aa 245 8 rios a haha rend 113 16 11 4 EECH E EEN 113 16 1155 Porcino signal EE ries cae be 4 a SESS aw Sees e A 114 16 11 6 Forcing digital output 3 4 u es su aa wa HEE SEG EEE ESS 114 16 11 7 Hard Software Codenumber ee lt u ed eu u Er an Ha BS 114 16 12 Examples of configuration A v0 4 40 2 2a 0 Seo ha aa EERE ODES 115 Parameters c a6 oss Bere ARA a an 117 17I General o EA AA A REPS See Re ee 117 17 1 1 Allocation of parameters to the extended operating level 117 17 2 Set point Function e ss AP ak Ge bed a a a a hate ak RSS 119 17 3 Time function sse msarap anpi ERROR OSH ARA 119 17 4 Programmer functions 4 4 errada AAA 119 17 3 Aar ZEIL ar ee EA 120 IO Sel a ts a eo Ew Se we OS RA A A DAA 120 67 Controlalgoriinn dro AREA 121 17 9 Input processing ge e e e Ga a u irn ge 122 17 8 1 Process value handling ek 2 ia ar ra AAA 122 17 8 2 Signal pre processing 4 e ea ae ei a 122 EE ara a RS ae AAA 123 AA EII ST NS 123 VErSIOnS EN die A ORS a ESSE ESAS HES SSS 125 18 1 Industrial controller KS92 roses oD OR Ge SESE EG HES SER 123 18 2 Industrial controller KS94 carteras He Ge hw e RLRE Ei 126 18 3 Input and output allocation with pre configured units 127 Terminology explanation 2 6 5 26 6 os os
56. input di4 programmer start stop Control input di5 programmer reset Control input di6 program selection Control input di7 program selection Control output dol control output 1 Control output do2 control output 2 Control output do3 control output 3 Control output do4 control output 4 Circuit board C optional only possible with KS94 Circuit board C offers further configurable inputs and outputs Difference input INP3 disturbance variable z or process variable x2 ratio three element Difference input INP4 external set point We set point offset dWe override control OVC process variable x3 three element Current output OUT3 operating mode continuous 0 4 20mA or logic 0 20mA function configurable Control input di8 selection control parameter set 1 4 Control input di9 selection control parameter set 1 4 control input di10 override control OVC with three point stepping controllers Control input dil 1 override control OVC or set point correction dW e On off Control input dil2 w W2 switch over Control output do5 positioning signal yl switching controllers or A M status Control output do5 positioning signal y2 switching controllers or i e status 23 User manual KS92 94 KS92 94 function survey 5 2 Survey of included function modules A survey of function modules and their interdependence is shown below The individual function modules are described in the following sections
57. is continued at the point time mark in future or past at which process value and program set point are equal Relative program time in segment and rest time are corrected accordingly If searching in the actual segment is not successful the programmer behaviour is as follows Fig 72 b f The programmer repeats the actual segment with The programmer skips the actual segment and starts at the beginning of the next segment if lo the gradient 0 or if the gradient gt 0 and X gt Wi or if the gradient gt 0 and X lt Wi 1 or if the gradient lt 0 and X lt Wi if the gradient lt 0 and X gt Wi 1 Bumplessness is achieved by controller gradient limitation Grw Grw Fig 72 Automatical search mode a Successful search mode b Gradient 0 x gt w oder x lt w S i S i Sis S i Sa i Sau n 1 n 1 Failure Return Failure Return c Gradient gt 0 x lt w d Gradient gt 0 x gt w S S So S Sn i So n 1 n 1 Failure Return Failure Return e Gradient lt 0 x gt w f Gradient lt 0 x lt w S S i Sa S Sn E Sms n 1 n 1 Failure Return Failure Return User manual KS92 94 86 12 07 2000 Programmer 13 6 Behaviour after mains recovery and after removal of sensor errors 13 6 1 Memory loss RAM With memory loss the last program set point and the time elapsed so far are not avai
58. of 0 4 20 mA and 0 2 10 V signals is possible The physical unit can be configured This input is a difference input Terminal A9 is used as reference potential Common With voltage signals terminal A6 must always be connected with terminal A9 The input resistance is 50 Q as mA input and gt 100 kQ as V input For the 2 10 V or 4 20 mA standard signals the output action with sensor break can be determined gt EMBA and EH 3 Moreover the decimal point i e the digits behind the decimal point can be selected HDD Additionally a physical input scaling by determination of 0 and 100 is possible gt EME and HD di For input value processing a filter time constant with a numeric value within 0 5 and 999 9 can be adjusted SEM Configuration is in the following order C 400 gt E MD 1 ENDE EMS EM EA See also external set point Wext page 45 and ratio controller page 49 User manual KS92 94 34 12 07 2000 5 6 5 5 6 6 12 07 2000 KS92 94 function survey rue Signal input 6 INP6 auxiliary variable yp position feedback yp gt E450 The signal for auxiliary variable yp or position feedback is configured at analog input INP6 if this was selected during controller configuration For this input the decimal point and thus the digits behind the decimal point can be selected gt 1 450 Moreover a physical input signal scaling by determination of 0 and 100 is possible 3 45 and ESE The output
59. of the process value signal see Fig 62 correcting variable y Switch over is at adjustable trigger points of the correcting variable see Fig 62 ZA DD Un control deviation xw Switch over is at adjustable trigger points of the control deviation see Fig 62 User manual KS92 94 78 12 07 2000 Programmer 13 1 13 1 1 12 07 2000 General Programmer definition The KS9x programmer has analog output and 4 control outputs 1 4 digital A survey of the most important features 1 analog output 4 control outputs 20 segments individual segmentation common control commands run stop reset 3 programs recipes KS92 only 1 program each with common preset to time or segment start Programmer Control outputs are not firmly coupled to the analog output segmentation They are provided with individual segmentation which is common for the control outputs This means that number of segments and overall time sum of segment times of analog output and control output can be basically different Fig 62 Programmer definition 18 analog output PRESET PRESET control output 1 control output 2 control output 3 control output 4 il START expired programmer time END With respect to control signals and programmer visualization the analog output is the master output Le
60. overshoot with important load changes Example steam boiler Nominal pressure Pn 18 bar at 50 load Pressure limits 18 5 bar no load 17 5 bar full load Measuring range 0 20 bar 2 4 20 mA Xo X100 of INP1 Solution Three solutions are possible All required functions are provided as standard U Simulation of an increased process value yp INP 6 is calibrated as usual Xo X100 and displayed as a position As with every input two phase pre processing is also provided in INP6 E 4 4 selects auxiliary variable z via INP6 with or without differentiation Scaling mx b is used to calculate the correction characteristic for lowering the set point a positive m and a negative b must be adjusted m 18 5 17 5 bar 100 0 01 b lbar L Lowering the set point As above but set point cascade with external offset dWe E 1817 is set E HB selects the INP6 as source of dWe As the correction characteristic acts on the set point the polarity of m and b must be reversed In this case differentiation is not possible 0 01 m b 1 bar 57 User manual KS92 94 Special Functions U Position feedback as standard signal With yp measured via an external transmitter connection of the current signal either as auxiliary variable z or as external set point offset dWe to the relevant inputs and scaling it directly to the required correction range z B 0 100 1 1 bar with Xo X100 is possible
61. the outputs OUT1 OUT2 OUT4 OUTS unless used by other signals can be used for limit value or alarm signalling Each of the 4 limit values LIM1 LIM4 has 2 trigger points L i mH Max and LimL Min which can be switched off indivudally parameter The switching difference Lx 5 of each trigger point is adjustable Fig 46 operating principle of relative limit contact LimH LimL 999 Ww 9999 393 W 9399 xa y o BEI xB y 2 100 lt LimH gt lt LimH lt Limb Lxsd k Jus lt LimL Lxsd lt Siz LED gt lt LED normally closed normally open selection in 1 500 ff mode Limb adLimH correspond to values C A 00 ff amp tw at which there will be an alarm Fig 47 operating principle of relative limit contact LimH LimL SS e Ge pe y o e lt LimL LimH gt lt LimL X LimH gt Lxsd K tt Lxsd E lt hep reo gt lt l normally closed normally open selection inf 500 ff Mode L el andL imH correspond to control deviations which cause the alarm Limit values below the set point must be specified with negative polarity sign The variable to be monitored can be selected separately for each alarm via configuration The following variables are available effective process value Limit contact
62. transducers are monitored for break and short circuit Current and voltage signals With current 0 4 20 mA and voltage signals 0 2 10V monitoring for exceeded range I gt 21 5 mA or U gt 10 75 V and for short circuit I lt 2 mA or U lt 1 V with life zero signals is provided Sensor errors can be output as control signal In case of error upscale or downscale action of the input ciruits are possible Moreover a substitute value can be defined with controller KS94 Unless the main correcting variable but e g external set point set point offset or external output limiting are concerned control can be continued also with failure of an auxiliary variable After removal of a sensor error the controller waits until the input signal has settled approx 10s before the controller is initialized outputs switched off during several seconds Scaling Standard signals mA and V are scaled according to the physicl measuring range of the transformer x0 x100 With potentiometric transducer measurements INP1 INP6 calibration is according to a well proven practice oriented method Bring the transducer to span start and then to span end position and calibrate it for 0 or for 100 by pressing a key at parameter level Calibration is basically a scaling procedure whereby gradient and zero correction are calculated automatically via the firmware Linearization Generally thermocouples and Pt100 are meas
63. x w W2 x x x Auto Man xXx X PL P x x Y Y2 x x Controller on off x x Programmer Run Stop x Programmer Reset x Selection of programs x x Remote Local x Parameterset x x OVC Three point stepping x controller OVC Three point stepping x controller disabling D x x OVC off on xX U Function allocation of outputs Functions OUT OUT2 OUT3 OUT4 OUTS dol do2 do3 do4 doz do6 Controller output 1 x x x x x x Controller output2 x x x x x x Alarm 1 x x x x Alarm 2 x x x x Alarm 3 x x x x Alarm 4 x x x x Process values x1 x2 x3 Xeff x x Set points W Wett West dWext WI X x Control deviation xw x x Correcting variable Ypia x x Position feedback Yp x x Contr outputs 1 x x x Contr outputs 2 x x x Contr outputs 3 x x x Contr outputs 4 x x x Program end x x Status auto man x Status Wint Wext x 1 auto manual key disabling set point adjustment controller switch off value adjustment and programmable controller operation 12 07 2000 39 Handbuch KS92 94 KS92 94 function survey User manual KS92 94 40 12 07 2000 Set point functions e Set point functions 6 1 Terminology 6 2 12 07 2000 w internal set point we external set point wp programmer set point W2 second internal set point Weff effective set point SWi e signal source for internal external set point sw
64. 1 Process value x1 1 set point disp Weff 02 F 08 1 min 2 Process value x2 03 99 freely selectable 3 Process value x3 04 mbar Engineering toolnecessary 05 bar User manual KS92 94 112 12 07 2000 Configuration 16 11 AUX Additional functions The interface function and operating frequency for suppression of interference on inputs are configured 16 11 1 COM serial interface Mainconfiguration 1S01745 PROFIBUS Only with HW option B Prot Baug Interface protocol Baud rate o Interface address 0 150174 00 not adjustable 1501745 01 2400 Bd 0 99 default 0 02 4800 Bd PROFIBUS DP 03 9600 Bd 1 128 default 128 04 19200 Bd 16 1 2 Hardware The hardware related functions are configured Main configuration Operating frequency for suppression of interference on inputs is configured Era Mains frequency 0 50 Hz 1 60 Hz 16 11 3 Forcing signal input All configuration for forcing ar only present by PROFIBUS DP FIHFi FIHFS3 FIHF4 FIHFS FIHPE Forcing input 1 Forcing input 3 Forcing input 4 Forcing input 5 Forcing input 6 0 Controller value 0 Controller value 0 Controller value 0 Controller value 0 Controller 1 Forcing 1 Forcing 1 Forcing 1 Forcing value 1 Forcing 0 Controller value 0 Controller value 0 Controller value 1 Forcing 1 Forcing 1 Forcing 1 PROFIBUS automatic ba
65. 3 we hak eS E ar RR a are ok Hae Be A d 98 16 4 CONTR Controller AA HO AA A 99 16 5 SOURCE Input signal allocation 2 444 44 ews oak RA RA A 101 16 6 INPUT z 468 fs db ot Bae Gy ees PS BAe 2S OS Se Se De bare oes 103 16 6 1 Signal input 1 INP1 main variable xl 103 16 6 2 Signal input 3 INP3 ratio variable x2 or auxiliary variable z 105 16 6 3 Signal input 4 INP4 variable x3 ext set point Wext override control ovct 106 16 6 4 Signal input 5 INPS ratio variable x2 ext set point Wext 106 16 6 5 Signal input 6 INP6 auxiliary variable Yp feedback Yp 106 LO OUTPI e neoe teea miea de elie Di Ae A wt Bde a Tm Os 107 167 07 Signal output 17 OUT s e 25 8 04 Su Bear sr sei EES HGF 107 16 7 2 Signal output 27 OUT2 zu eke za dw aw eee OS KER 108 10 13 S onaloupul 37 OUTS 44 245 eta eH ara sei rien EER 108 16 7 4 Signal output 4 QU A 0 gn sau Ra eS 109 10 0 1gnaloutput sy OUTS 2 2 5 Zeg Sa Erie 109 16 7 6 DO5 6 digital control outputs 44 4 4 da 48 so Ok er nen 110 16 8 ALARME y 2 00 0 0 vr OR a RS Bee oe Be ee ae OR Boe ee eS 111 168 1 Alarm 7 limit I sse 6 a Dak Sod OG Roe we GEE ES GH 111 16 8 2 Alarm 2 limit2 rca Rw Oo aa hr er er 111 16 83 Alarm 3 mit 3J e e cara o rare 111 16 8 4 Alarm 4 limit 4 aaa a a 111 16 9 TUNE SUSUDIDS lt q okay aade aa EES A A ke 112 16 10 DISP User interface for operation 2244 22 ss 2324 1a a e 112 16 11 AUX Additional
66. 4 function survey 5 1 5 1 1 5 1 2 5 1 3 5 1 4 12 07 2000 Basic hardware functions Various KS92 94 controller versions according to order number are available Decisive for the hardware is the number of connected circuit boards i e connectors A large number of standard applications can be realized only with the KS92 94 basic version which contains circuit boards P and A The input and output functions shown in the following correspond to the basic setting Finally however the individual configuration is decisive Circuit board P Output OUTI positioning signal OUTI can be ordered as a current or relay output Dependent of selected controller type it can be operated as a continuous 0 4 20mA signal or as a 0 20mA logic signal Output OUT2 positioning signal Output OUT4 limit signal alarm Output OUTS limit signal alarm Circuit board A Universal input INP1 process variable x1 process value Difference input INP5 external set point We Measurement input INP6 Position feedback yp with 3 point stepping and continuous controller Control input dil set point switch over Control input di2 automatic manual switch over Circuit board B optional Circuit board B contains a serial interface TTL or RS485 ISO1745 and MODBUS protocol a real time clock and additional control inputs and outputs which are reserved exclusively for the programmer functions Control input di3 remote local mode Control
67. 7 User manual KS92 94 Optimizing the controller 11 2 3 Three point controller Adjust cycle times T and T2 at configuration level They correspond to the minimum cycle times at 50 duty cycle For optimizing according to the control response the hints given in Fig 3 must be followed Wise iga Fig 52 Static operating principle of the H 2 100 three point controller Y c 0 Hed Xp Xp PD PD behaviour In The adjustment range reaches from 100 heating Y1 to 100 cooling Y2 The proportional bands must be matched to the different heating and cooling rates For keeping the process lined out a certain amount of energy dependent of set point is necessary This results in a permanent offset which will increase with higher Xpy1 2 DPID DPID behaviour By means of the integral action the process is lined out without permanent offset The transition from trigger point 1 heating to trigger point 2 cooling is without neutral zone The proportional bands must be matched to the different heating and cooling rates Fig 4 The drawings in Fig 52 show the static characteristic for inverse and direct action Direct inverse switch over only causes the exchange of the outputs for heating cooling The terms heating and cooling are used for all similar processes batching acid lye The neutral zone is adjustable separately for the trigger points Xsn7 Xsn2 i e it need not be symm
68. 8 and STk 2 XFail o substitute value with sensor error le numeric value 999 9999 ut Tim o i filter time constant for input value processing Oo ID numeric value 0 0 999 9 gt TFM ot filter time MU Optional configuration 1 o The optional configuration can be used to determine the functions O for two signal pre processing levels REDERIET Funel Funcz LDF Function selection for signal pre processing decimal point for gain Xeff and yki 0 no function signal is output directly 0 no decimal point 1 scaling parameters m b 1 1 digit behind the decimal point 2 linearization segment points xs1 ysl 2 2 digits behind the decimal point 3 filter parameter Tf 3 3 digits behind decimal point 4 square root extraction with factor parameter gain 1 The Fail adjustment does not affect the controller behaviour With sensor error the controller behaviour is always as determined in il i C a i 1 The signal behaviour with sensor error acts only on a configured alarm With a process value zl or INP1 alarm configured the signal goes e g to the upscale value X100 with sensor error User manual KS92 94 104 12 07 2000 Configuration More value pair 1 value pair 2 o Note that the input values x values must be entered in ascending order Value pair 4 xs1 lt xs2 lt xs3 value pair 5 value pair 3 value pair 6 value pair 7 value pair 8 in 999 and 999
69. 9 or switched off For limiting the number of parameters these functions can be used only once during pre processing levels or 2 Linearization segment points which are not required can be switched off by setting 16 6 2 Signal input 3 INP3 ratio variable x2 or auxiliary variable z In this case the signal is configured for ratio variable x2 or auxiliary variable z provided that option p c b C is fitted in the controller and the function was selected during controller configuration Main configuration Selection is only possible with option p c b C provided Dr Number of digits behind the decimal point 0 no decimal point 1 1 digit behind the decimal point 2 2 digits behind the decimal point 3 3 digits behind decimal point Standard signals 30 0 20 mA 31 4 20 mA Additional configuration The additional configuration can be used for changing or matching the signal input default setting for the sensor type More add confia Signal behaviour with sensor error 1 upscale X100 2 downscale X0 3 XFail 1 3 13 12 07 2000 105 User manual KS92 94 Configuration The other configuration words for INP3 are explained in section see following table optional configuration EBEN 8 without linearization Func1 2 2 16 6 3 Signal input 4 INP4 variable x3 ext set point Wext override control ovc The signal for three el
70. Digital outputs Display 1 Display 2 E Electrical connections F Front view Function library Filter LAGI Linearization CHAR Scaling SCAL Square root SQRT Galvanic isolation Gradient function Grw Grw Grw2 I Input 0 2 10 V Input conditioning Filter Input circuit monitor Linearization Measurement value correction Scaling Interface Switch over bus gt front panel Switch over front panel gt bus L Local M Mean value MIN MAX selection Mounting 63 113 85 133 O Operation Menu 1 3 sch Parameter and configuration level The operating level Operation local Output action Override control PC interface Process characteristics Process value tracking programmer search mode Programmer Change mode ramp step control signals and status messages Parameter entry Preparation for operation recipes R Rapid Recovery Ratio controller Remote Remote local Resistance thermometer S Safe set point W2 Second set point W2 Self tuning Messages Process at rest monitoring Set point reserve Sensor break Set point tracking Signal input INPI INP3 INP4 INP5 INP6 Signal output OUTI OUT2 OUT3 OUT4 OUTS Signallers Standard signal 0 4 20 mA Status indication SCH Stoichiometric combustion T Thermocouple Three point stepping controller Three element control Three point controller Time Ind
71. Dr E 69 11 2 5 Three point stepping controller 2 er 0 na erde ad 70 11 230 Continuous controller A ss gear 64 sa nu a haha 71 11 2 7 Continuous controller with position control 72 Optimizing the controller zus u 6 0464 E SOO OH AE AA eR Ae 73 LAR nme en ee A He Se RE OO Boe ee Se den 73 12 1 1 Process at rest monitoring a 44 ur a aaa end Bee es 13 12 12 Setpoint TCSEIVE 40 0 E a mp EE EE E eM a Bw ea 73 12 1 3 Start during automatic operation ic rivas ha 74 12 14 Start during manual operation es 4 4 203 4 ve E EE A 74 12 1 5 Self tuning procedure with heating za u sa au a sa Bae we Sw 75 12 1 6 Self tuning procedure with heating and cooling processes 75 12 1 7 Signification of self tuning messages MSG1 MSGZ 76 12 2 Optimizing empirically sses a Wa aa eau e e a He YRS a 77 12 3 Selectable adaptation only KS94 ass aan adie we eR Se SE eS a eS 78 Programmer es doces es ga ora Oo 4 A DOSS oS EOS a 79 EMBLEMA 79 IBAI Programmer definition ess ro RAE E a 79 134 2 Segment parameter eniry 3 gn ege pona AA oS 80 13 1 3 Parameter pre setting default isos ss a 48 wanna AR 80 13 14 Time display s cessan goes ewe IA AR A eee a A 81 13 1 3 Elatramps ers eo oP ee A EI wo de AAA 81 Sige Programs teCip s e ss de w acn taa wide EE ee ee ee rel 81 13 1 7 Change mode amp sis a 24 aed aS we oR we oR a aoe es 83 13 1 8 Preparation for operation and end position za 4 244 2 44 4 24644
72. Fig 11 Survey of functions INPUT Pre processing INP 1 kapp o 2 0 8 serial interface Operating and display CONTR TUNE Func1 H Func2 INP 5 Set point processing Self tuning Func1 Func2 INP 6 Func1 j Func2 di1 Ww We Set point Wp amp connecting W2 Se di2 INP 3 HH Func1 H Func2 PROG N Control and monitoring Self Controled tuning adaption INP 4 Func1 H Func2 di 8 Process value processing di 9 Signalprocessing 5c di 10 di 11 di 12 di 4 Ratio 1 2 3 3 element mean value Yp signal di5 di 6 di7 Disturbance conditioning D PID Controller Corr var processing Signalprocessing Src OUT 1 Limit value processing OUT 2 OUT 4 OUT 5 OUT 3 Auxiliary variable z Output limiting Automatic manual Y Y2 ect di 3 R L User manual KS92 94 Remote local switch over 24
73. H EEE E and set point W during start up 5 set point risk Y 6 Finished Optimization cancelled due to exceeded set point risk reversal point not reached so far safe estimation Cancellation A Cancellation Increase Ma or reduce YORLM Insufficient output step AY lt 5 Ymax y 7 AY lt 5 Y nn Cancellation Change stable correcting variable YOF tm Set point reserve insufficient or ros wo wioo 8 set point exceeded during PiR E monitoring gt Unless control is functioning properly as required despite self tuning proceed additionally as described in section 12 2 page 9 Optimizing empirically Moreover the specifications on further parameters must be taken into account User manual KS92 94 76 12 07 2000 12 2 ee E 12 07 2000 Optimizing the controller Optimizing empirically If process data are missing empirical optimization by means of self tuning or by manual attempts is possible When attempting empirical optimization the following information should be taken into account Ensure that correcting variable and control variable will never reach inadmissible values L In order to have comparable results the conditions for the attemps should be always identical The attempt procedure must be oriented at the target of optimization control behaviour or disturbance behaviour L The controller working point must be equal with the attempts When using t
74. Hg 5 IAN Dit 5 ruin Lit tu 3 Optional configuration 1 without linearisierung Func1 2 2 User manual KS92 94 106 12 07 2000 Configuration 16 7 OUTPT 16 7 1 Signal output 1 OUTI Used for configuring the source of output OUT1 This signal output is a universal output which can be configured for extensive functions Main configuration She Tyre Mode Signal source Output stage Motor actuator output action 00 output switched of 0 relay switching 0 not selectable 01 controller output Y1 Youtl 1 0 20 mA continuous output 1 direct normally open 02 controller output Y2 Yout2 2 4 20 mA continuous output 2 inverse normally closed 03 output Ypid 3 0 20 mA logic 04 position feedback Yp 05 controlling deviation Xw 10 process value Xeff 11 X1 12 X2 13 X3 20 set point W 21 external set point Wext 22 external offset dWe 23 set point Weff 24 programmer set point Wprg 25 alarm 1 limitl 26 alarm 2 limit2 27 alarm3 limit3 28 alarm 1 limit4 Additional configuration Out1 Via the options configuration the functionality for a signal post processing stage can be determined rad p g y gnal post p g stag EE This configuration word is displayed only with the option enabled Furic Dr Function selection for signal output decimal point for xsi x0 x100 0 no function signal is output 0 no decimal point withou
75. P4 galvanically isolated or INP6 yp input BH if necessary Signal pre processing Funcl Func2 permits adjustment of the required set point or correction characteristic as a function of the input signal dependent of configuration gt INPS L 3 12 INP4 0 420 or INP6 4 18 Internal set point W has priority If the internal set point was selected anywhere front panel interface or the relevant control input switching over to external set point We at another facility is not possible 12 07 2000 45 Handbuch KS92 94 Set point functions 6 6 6 7 6 7 1 Set point offset The Set point offset internal dW or external dWe can be added to the effective set point or multiplied by it L 6 dl Examples for an additive set point offset are reduced stand by set point and outside temperature dependent supply temperature control Set point offset as a factor can be used e g for split load or O2 correction Dependent of configuration the set point offset can be triggered via interface front panel operation or via one of control inputs dil di2 or dil 1 gt E 38 Son For activating the set point offset a 1 signal 24 V must be connected to the relevant contact For de activating the set point offset a 0 signal 0V must be applied to the contact Analog input S Wd is connected to INP5 however it can be configured also for INP4 galvanically isolated or INP6 yP input 80 Schl if nece
76. P6 gt ouT4 We nn Top sensor type AD outs d d Src 1 controller output y1 990 Spe 25 alarm 1 2 pnt controller 2 process value alarms 9407 9xx xxxxx LIDD CFuric 03 3 pnt stepping C59 Src 26 alarm 2 INP1 i rue Toun CTF 0 standard controller Coen Src 03 process value x1 INP5 3 gt D our2 ll Num 0 1 4 or 5 INP6 i aan oura Weck TF sensor type gt gt D ours d 30 Src 01 controller output y1 530 Src 02 controller output y2 3 pnt stepping controller process value alarm 9407 9x4 xxxxx C100 CFurne 10 continuous 530 SPC 28 xw alarm ner Lei 2 0UT1 CTF 1 ratio controller d 30 Src 25 alarm 1 INP5 gt 0lourz an YEung 0 1 40r 5 fad Sic 26 alarm 2 mpe el In ours EIET 5 2 1 INP5 CEDI Gre 02 xw alarm AD ours EDD Tur ooo Gre 01 xef roan sensor type LEAD xeff gt Base Src 01 controller output yl Src 03 process value x1 Ratio controller continuous 1 xw alarm 2 process value alarms 9407 9x4 1x2xx 160 CFune 10 continuous 530 Src 78 alarm 4 INP1 x 3l OUT1 CTF 1 standard controller SE Sra 33 program end INP5 Ss i our ms WFur 3 programmer LIDD Sra 02 xw alarm INP6 A w_ n oura ie SPrSt 1 di4 did staristop Enge l OUTS Eb d TF sensor type dis au Daun SC Ol controller output y1 Programmer continuous 1 xw alarm 9407 9x4 x1xxx LIDD CFure 11 continuous split range d 30 Sree 25 al
77. PMA Proze und Maschinen Automation GmbH PMA Industrial controller KS92 94 KS92 94 User manual 9499 040 44811 valid from 8365 DACH isa patented method and a registered trademark of Regeltechnik Kornwestheim GmbH PMA Proze und Maschinen Automation GmbH 2000 Printed in Germany 0007 All rights reserved No part of this document may be reproduced 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 Subject to changes without notice PMA Proze und Maschinen Automation GmbH P O Box 310 320 D 34113 Kassel Germany Contents General hints ee ee te te 9 1 1 Technical datt os woke ke sip te Bw eo ok aoe Mek PS Pe Ee Go re oe oe Bad 10 1 1 1 Safety Oley 2 a4 o oe Oe a a eee Ee ae ee 10 1 1 2 Electromagnetic compatibilizar a Sg 10 1 1 3 Maintenance Behaviour in case of trouble 10 1 1 4 Electrical Connections eos sss Sr Er rear green 10 Mounting and CONNECTION lt 4 6 6 4 5 44 ug AAA AA 11 AR AA ee ee Be oe Bae a ooh wie Re a Soe Oe oh a 11 2 1 1 Removing the controller from the housing 12 2 1 2 Installing the controller in the housing 34 ocasiona eee 12 Electrical connections 4 au ese wann u aa ROR ar anne 13 3 1 Supply voltage connection r 14 3 2 Connecting the analog inputs INP aser Se EE des 14 a DEP E D KSE 15 34 Dig
78. actually required set point is done slowly according to parameters Grw Whether process value or set point tracking is required is determined in configuration code C 106 WTrac Dependent of configuration this setting can be made via interface front panel operation or one of control inputs di2 or dil2 gt 138 However the type of switch over is only prepared at this facility without actually selecting between external and internal set point For preparing bumpless switch over a 1 signal 24 V must be connected to the relevant contact For direct switch over a O signal 0V must be applied to the contact Bumpless switch over has priority With bumpless switch over selected anywhere front panel interface or relevant control input switching over at another facility is not posible Fig 21 Process value tracking with switch over to internal set point W Set points process value X ae A we wp upper set point limit W100 AA internal set point w internal Da ee se set point w i lower set point limit WO 7 A mo Switch over Switch over We Wp gt w w gt We Wp 6 8 3 MIN MAX selection WSel Dependent of set point WSel configuration effective set point Weff can be prevented from being below or above the value determined by analog input INP3 OL 76 This function can be used for instance during combustion control whereby excess air is indispensable crosswise interlocking of air and fue
79. adas wo ee PER oH aw A 27 5 4 5 EINER 27 5 4 6 Scanning A ee ee ae we ee E SR ws 27 5 4 7 Li catization CI OF ao x sore eon oe a a we ee 27 5 4 8 Temperature compensation cecce ca saa Sa 3a Da eds we os 27 5 4 9 Measurement value correction optional 28 Signal pre processing rra ee hb Sead GREE EEE RRS ED EE HH 29 IOUS e eae Geb De Ama da BERS ea ea a se 31 5 6 1 Signal input 1 INP1 main variable x1 gt L 200 31 5 6 2 Additional signal input 3 INP3 optional AL 300 34 5 6 3 Additional signal input 4 INP4 optional gt 358 34 5 6 4 Signal input 5 INPS ratio variable x2 ext set point Wext gt HUDA 34 5 6 5 Signal input 6 INP6 auxiliary variable yp position feedback yp gt as 5 6 6 Digital inputs e sa soa EEES wih aw AS BO oe 35 MOUNTS a E A a we wee ee a A RE ED 36 57 1 Signal output 1 OUT1 gt SUD 22 44 20 BE Br ann 36 5 7 2 Signal output 2 OUT2 gt SJD Ee a ra as 36 5 7 3 Additional signal output 3 OUT3 optional gt E ABB 37 5 74 Signal output 40UT4 gt ESIB 2 3 6 4048 EN aa weeds 38 STS Signal output 5 OUTS gt L S 1 32 24 u 2 RR a ne 38 5 7 6 Digital outputs dol to do6 az ok eds oa hase ehe 38 ST Input and output RENE s si ew ra Raw Be rn 38 G Set pomt TURCOS u 2 ses as a OR SRST HERES a ES 41 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 Terminology dm is oes Sew ohm as woh oA OS Ue hr 4 E aa y Se Bie eda ee
80. age 38 Outputs OUT4 and OUTS are allocated to alarms LIM1 LIM2 With programmers they can be configured in addition to outputs 1 4 or for program end 598 59 1 see page 38 Output OUT3 Dependent of configuration OUT3 is a continuous or a logic output The logic signal switches between 0 and 20 mA load lt 600 Q or 0 and 12 V load gt 600 Q Which signal shall be taken to this output must be determined at configuration level Selection between various controller outputs process values and set point is possible see page 37 3 4 Digital inputs di Digital inputs dil and di2 O Dependent of configuration 130 and E 1 1 inputs dil and di2 can control the following procedures Switch over between internal set point W 0 and externel set point Wext 1 Switch over between internal set point W 0 and second set point W2 1 Switch over between automatic 0 and manual 1 operation Set point offset switch on normal 0 offset 1 Switch over between normal correcting value 0 and safety correcting value 1 Controller switch ON 0 or OFF 1 Switch over between PI 0 and P 1 with 2 3 point and continuous controllers or feedback switch off with 3 point stepping controllers e Bumpless switch over between normal correcting value 0 and safe correcting value 1 e Bumpless switch over to internal set point tracking only di2 OFF 0 ON 1 Digital inputs di3 to dil2 O VES
81. alue de Position feedback Hd Control deviation xl Main input xl Hz Auxillary input x2 E Auxillary input x3 zZ Auxillary variable UU External correcting variable limiting ett Effectiv process value FIRUT Input signals IHFi Input 1 IHFir Raw measure 1 IHP Input 6 IHFEr Raw measure 6 TO Programmer signals WF Programmer setpoint tErut gross time inc all pause times tHet net time without pause times tFRe st Resttime PHr Programmer no 1 35 1 Clock Current time 12 07 2000 123 User manual KS92 94 Parameters User manual KS92 94 124 12 07 2000 Versions 18 1 Industrial controller KS92 12 07 2000 POWER SUPPLY AND PROCESS OUTPUTS OPTION B ADDITIONAL FUNCTIONS PRECONFIGURATION 141017 KS 92 KS 92 with two wire power supply 230 VAC 4 relays OUT1 OUT2 OUT4 OUTS 230 VAC 3 relay current logic output OUT1 OUT2 OUT4 OUTS no interface TTL interface and 5 control inputs di3 di7 and 4 control outputs dol do4 RS422 and 5 control inputs di3 di7 and 4 control outputs dol do4 and clock no additional function Measured value correction Measured value correction and programmer standard setting 2 point controller 3 point stepping controller Continuous controller current logic output required 3 point controller logic relay current logic output required Setting to specification manual required
82. and program continuation are in this segment For unsuccessful search mode Fig 73 Behaviour after mains recovery and sensor fault a Automatical search mode b process value transfer and wait e S S n 1 n 1 Sit i S i Saat mm Wint x eee bei X Tracking Failure Return Failure Return c Continue program S Sa Sur n 1 Failure Return 13 7 Preset Preset sets the programmer to a defined point which is determined according to PMade by e a segment start preset to segment Prade 0 or e by a preset program time preset to time Friade 1 Preset value and command can be preset at the extended parameter level page 89 and via serial interface Any set point differences are removed bumplessly with the controller gradients Grw 13 8 Sensor fault With primary variable sensor fault the programmer is stopped After removal of sensor faults the programmer behaviour is as after power failure gt 13 6 2 12 07 2000 87 User manual KS92 94 Programmer 13 9 13 9 1 13 9 2 13 9 3 13 9 4 Programmer displays Display 1 The actual process value is always displayed on display 1 Display 2 The actual set point is displayed at operating level on display 2 At extended operating level program times and actual programmer recipe number are displayed on display 2 C t20 PSe1 0 Format of display 2 8 6 59 hours minutes
83. anged Tp1 Tp2 Tp3 Tp4 Tp5 during segment time Tpi Tp2 e Tpp Tp e Ramp ES The set point changes linearly within time Tpi from Segment 3 ee start value Segi end value Wpi 1 of the gend previous segment Segi 1 in the first segment process value x to the end value of segment Wpi BK A For the first segment the following gradient is applicable Wn Fig 67 Gradient priority Tpl Gradient priority om With configuration ramp with gradient priority controller start up is always followed by a search run which may lead to a time V reduction in the first segment In general the time is adapted at lt tp eff gt each search run and the gradient remains constant POE ABE REIS A E p gt Time priority In ramp with time priority configuration controller start up will Fig 68 Time priority always be followed by a search run which may lead to a change z of the start set point in the first segment In general the gradient wp is matched with each search run and the time remains constant ra Preparation for operation and end position Each program starts with a start position Wpo which is valid after Wie tp gt resetting or setting up the programmer for the first time until further changes are made With program start from the rest position the first programmer segment starts from the instantaneous process value at the time of the start command
84. ard Software Codenumber The following configuration dates are not changeable They show the hardware version 2 99 1 u 992 and the software version 993 u 99 of the instrument Example 9407 923 31201 Example 4012 157 25320 IJ ST 3032 L A ut i hot A A Da Mo 1 an User manual KS92 94 114 12 07 2000 16 12 Examples of configuration Configuration Block diagram Configuration different from default 9407 9x4 xXxxxx LIDD CFuric 10 continuous C590 Src 25 alarm 1 INP1 7 3 8 OUT1 CE Tar 0 standard controller tad SPC 26 alarm 2 INP5 gt gt our2 sin WE un 0 1 4 or 5 e DU Sra 02 xw alarm INP6 Jr 0 ouT4 Wee os Tr sensor type di b Src 03 process value x1 gt u gt D our d d SFC 1 controller output y1 LEID Sec 03 process value x1 gt o ES au Sra 28 alarm 4 Continuous controller 1 xw alarm 2 process value alarms 9407 9xx xxxxx LIDD CFunc 02 2 pnt controller 59 Src 26 alarm 2 INP1 7 Heizen 2 OUT1 CTF 0 standard controller di ED Sra 03 process value x1 INP5 A our ar WFurc 0 1 4 or 5 CBHD Src 03 process value x1 IN
85. arm 1 L emm mg INP1 A gt e OUT CT ur 1 standard controller d F a 26 alarm 2 INPS Ay Bl our I on WFurc 0 1 4 or 5 Bub SPEC 02 xw alarm INP6 Y Gef oura Ben TF sensor type Cob Src 03 process value x1 INP3 T MM ours d d Src 01 controller output y1 INP4 gt 8 oura_ 550 Src 02 controller output y2 Continuous contr split range 1 xw alarm 1 process value alarm 115 User manual KS92 94 Configuration User manual KS92 94 116 12 07 2000 Parameters Parameters 17 1 17 11 12 07 2000 General This section gives a survey ofthe KS92 94 parameter data and general hints for parameter handling The parameter operation and effect on the controller operation are described with the operating principle The parameter setting dialogue is realized via selector key CO and increment decrement keys A V like at the other operating levels Press the selector key to select menu items input values within one level and to change to the next higher level TI Press the increment decrement keys to return to a lower level or to change input values The controller parameter structure is given on the following page All parameters are listed Parameters which are not relevant for a function configuration dependent are not displayed A selection menu can be displayed anywhere at para
86. as set point 1 If the transmitters used by the controller use a stoichiometric ratio 1 is exactly met with restless combustion With a process value display of 1 05 the instaneous air excess is clearly 5 The amount of air required for atomizing is taken into account by constant NO Para gt Inrut gt Ist gt HG mr For selecting a ratio controller the Ek YP lin LIDD must be entered Moreover configuration words LIDL UI must be taken into account Conventional ratio control Calculation so far required scaling of the ratio variables for a range of 0 100 x0 x100 If this method shall remain unchanged factor s must remain unchanged with respect to factory setting s 1 In this case the control deviation is formed according to relation w x2 x1 N0 x2 xw xl NO 2 x2 In this case the physical and the relative ratio are identical so that the displayed process value x1 x2 also corresponds to the relative ratio Everything is as usual The x1 x2 gt individual flow rates can be displayed with unit at the extended configuration level gt x2 gt INP1 INP5 3 fat x1 joghurt Additional possibilities of ratio control with KS92 94 The two requirements i e control of the relative ratio and display of the material flow rates in physical units are met by means of the material specific stoichiometric factor s For display of the individual material flo
87. ast e g reduction of segment time Tpi to lower values than the relative time already elapsed in this segment cause a program step to the start value of the next segment Set point differences are compensated bumplessly with the gradients Grw Grw already adjusted at the controller the programmer continues running Changes of the target value of the actual segment cause the segment gradient to be re calculated once for this program run in order to re calculate the new target value in the remaining segment time These and all other rates of change are limited by the pre set set point gradients Grw Grw With a program reset and start or with preset to an earlier time the final segment gradient is re calculated 13 3 Bandwidth monitoring When leaving the bandwidth LC max limit LC min limit the programmer is stopped The program continues running when the process value is again within the pre defined bandwidth Fig 71 only shows the operating principle of the static program profile Actually however the curve is delayed accordingly in the stop times Parameter LC max limit LC min limit Fig 71 Bandwidth monitoring A Wp X d Doras ES ACR EPE SES N A Process value x a GER J Set point profile 4 h lt gt Stop Stop Stop Time On instruments with software option Programmer bandwidth monitoring is also effective with programmer not configured controller operation Parameters LC
88. ation reversal point not found estimation unsafe 6 Finished optimization cancelled due to exceeded set point risk reversal point not reached so far estimation unsafe 7 Cancellation correcting variable too low AY lt 5 8 Cancellation set point reserve too low DR e 2 Self tuning result during cooling R 0 8 see ORes1 Tul Delay time heating R 000 0 999 9 s Ua 1 Vmax heating R 000 0 999 9 s Erl Process amplification heating R 000 0 999 9 Tue Delay time cooling R 1000 0 999 9 s Umas Vmax cooling R 000 0 999 9 s EPZ Process amplification cooling R 000 0 999 9 User manual KS92 94 120 12 07 2000 17 7 12 07 2000 Control algorithm Parameters Text 1 Description Range Default CPara Controller parameters Truls Min pulse length 0 1 999 9 s 0 3 Tr Actuator response time 10 9999 s 30 YZ Additional correcting value 105 105 0 Ymir Min correcting variable limiting 105 105 0 rex Max correcting variable limiting 105 105 100 VA Correcting variable working point 105 105 0 FarHr Actual parameter set 0 3 meds Switching difference of additional contact 0 1 999 9 1 LN Trigger point separation of additional contact 999 9999 0 med Switching difference of signaller 0 1 999 9 1 ssh Neutral zone Xw gt 0
89. be activated from two sources configurable HDD Test Ay e internal status alarms control outputs recipes bandwidth e Control inputs dil dil2 With several simultaneous statuses or control inputs the relevant texts are displayed sequentially at intervals of 5s User text 1 Bargraph User text 2 Bargraph Usertextn Bargraph User text 1 If the text display is triggered via control inputs di C A OD the statuses of the control inputs will be read also if they are not used for controller programmer function control User texts Text 2 can be activated by Text ES Status digital inputs 1 LIM1 dil 2 LIM2 di2 3 LIM3 di3 4 LIM4 di4 5 Control output 1 di5 6 Control output 2 di6 7 Control output 3 di7 8 Control output 4 di8 9 Program 1 di9 10 Program 2 dil0 11 Program 3 dill 12 Bandwidth LC dil2 93 User manual KS92 94 User defined texts User manual KS92 94 94 12 07 2000 Configuration Configuration 16 1 16 2 12 07 2000 General The KS94 controller configuration for quick and easy function selection during subsequent operation is described in this section During configuration the required functions are selected from a large variety of available functions The configuration determines the basic structure for solution of an application The configuration structure is designed so that determination of the required functions for a large number of
90. control deviation Limit comperator process value x1 process value x2 Input eventually signal pre processing Furic 1 page 26 a 63 process value x3 auxiliary variable z externals set point we external set point offset dWe effective set point Weff position feedback Yp controller output override control OVC selectable set point input Wsel pre processed process value inputs INP1 INP6 after input conditioning gt page 26 a 63 net program time gross program time program rest time 63 User manual KS92 94 Alarm processing The alarm function is also configurable switched off sensor monitoring signalling with sensor error of the selected signal source sensor monitoring measurement value alarm sensor monitoringg measurement value alarm with suppression after set point change and start up Measuring value alarm Measuring value alarm with suppression after set point change and start up 10 1 Alarm 1 limit 1 The function of this alarm is determined in configuration parameter L A E Alarm signalling is via output OUT4 if this was determined as Src 29 in the configuration E AHH 10 2 Alarm 2 limit 2 The function of this alarm is determined in configuration parameter bd Alarm signalling is via output OUTS if this was determined as Src 25 during configuration 1 5 I 10 3 Alarm 3 limit 3 The function of this alarm is determined in configuration parameter L A D Alarm signa
91. cted controller configuration are determined in this main group The signal inputs required for the selected controller function are displayed in the menu for configuration As during control function configuration a large number of applications can also be covered by determining the main configuration At the second level special cases can be matched and adjusted by additional optional configuration Max 5 signal inputs are provided on KS94 Analog inputs INP1 INP5 and INP6 are always provided INP3 and INP4 are optional inputs All analog inputs whether or not used for control can be used for monitoring purposes e g alarm processing Signal input 1 INPI main variable x1 Configuration is for main variable x1 This signal input is a universal input for which extensive functions can be configured Main configuration The main configuration word is used for determination of input sensor type and physical unit Additional input configurations can be determined using the additional configuration Tee Unit DF Sensor type Unit Number of decimals Thermocouple Resistance thermometer 0 at Top 30 40 0 no decimal point 00 Type L 0 900 C 20 Pt 100 99 9 850 0 C 1 C 1 1 digit behind the 01 TypeJ 0 900 C 21 Pt 100 99 9 250 0 C 2 F decimal point 02 Type K 0 1350 C 25 2x Pt 100 99 9 850 0 C 2 2 digits behind the 03 Type N 0 1300 C 26 2x Pt 100 99 9 250 0 C d
92. ctuator travel time Tm o Start e During manual operation select parameter HP AL and set it to 1 End a End ui an Ten ig 3an Thiet 0 CD al Eric cot Zu End Conte AECA z Hold Tune Al End sac 1 USt ar Limit THES Ob Cb Vrtal i Op EA Kalib Eins 6 e Procedure Y 1 is activated until no changes are measured any more via Yp The measurement value is stored as x Oc Subsequently Y2 is activated until Yp does not change any more This measured value is stored as x 000 The duration of adjustment from 0 to 100 is measured and stored as Tm Like HUG and x 1000 Yp Cal can be marked for the extended operating level Display signification Possible causes Calibration error Potentiometer too small e Not connected e Potentiometer polarity error e Operating limits The motor actuator must be able to withstand a short term 3 4sec operation close to its limits without damage Otherwise the operating limits specified for DAC are applicable see above 61 User manual KS92 94 Special Functions User manual KS92 94 62 12 07 2000 Alarm processing 12 07 2000 Alarm processing Up to four alarms can be configured These alarms are allocated to the individual outputs Generally each of
93. d 999 9 is adjustable gt E 2 14 For configuration proceed in the following order CeRi feb fede 205 L i L i 0 2 10 V input The input resistance is gt 100 kQ During configuration distinction of 0 10 V and 2 10 V is made For the 2 10 V standard signal the output action with sensor break can be determined E 13 Moreover the decimal point and thus the digits behind the decimal point are adjustable gt E 14 Additionally a physical input signal scaling by means of Xo and X100 is possible gt E Z I and L e For input value processing a filter time constant with a numeric value within 0 5 and 999 9 can be used gt L 2 14 For configuration proceed in the following order Coig ien i en L n L N Ed iH 33 User manual KS92 94 KS92 94 function survey 5 6 2 5 6 3 5 6 4 Additional signal input 3 INP3 optional 9t 300 This signal input is only available with option p c b C fitted It may be configured for ratio variable x2 or disturbance variable z gt 105 orf 82 Selection of standard input signals 0 20 mA and 4 20 mA is possible The physical unit can be configured The input resistance is 50 Q For the 4 20 mA standard signal the output action with sensor break can be configured 3 305 and 3 1 Physical input scaling is possible by determination of 0 and 100 31 30 and 382 Moreover the decimal point i e the digits behind the decimal poi
94. d for the action gt 4H 5 e For input value processing a filter time constant with a numeric value between 0 5 and 999 9 is adjustable gt E Z 14 e A process value correction is configurable gt 285 The order of configuration is as follows Leni beds Led HT Ed th 31 User manual KS92 94 KS92 94 function survey U Resistance thermometer input Resistance thermometer temperature difference With a resistance thermometer the signal behaviour with sensor break can be determined gt 205 Temperature compensation is not required and therefore switched off With temperature difference measurement calibration by means of short circuit is required Lead resistance adjustment can be done using e g the 10 calibrating resistor order no 9404 209 10101 Dependent of sensor type the controller must be configured for one of the following inputs e resistance thermometer Pt 100 with linearization e temperature difference with 2 x Pt 100 and linearization e linear potentiometric transducers For input value processing a filter time constant with a numeric value within 0 5 and 999 9 is adjustable gt Ex 14 The decimal point digits behind the decimal point and process value correction can be configured gt 2855 Configuration is in the following order CEO tg de 4 Ed 15 L Resistance thermometer Pt 100 The two ranges 99 9 250 0 C and 99 9 850 0 C are configurable gt E Z 05
95. d n Timer Lxsd4 End 2 EX CO y End 1 LimH4 Lxsd3 1 End LIM4 LimH3 Lxsd2 al Eng LIMS ENE Lima lt q LIMZ z Al I I i End PZA 1 Tr28 I eee y End Wet D20 Tri 1 Tze Wea eee LC End o Di Urze 4 End Tdi Tr28 Digit CH a awe gt m End Wei I elms Bien Vi Reces Oo Digit O a Let Recez a ec E a O End i Tdi Prext Digit a gt Prode zer End Bl Gye ree a en Eee E H Er i changing a parameter 1 TE MD L IVEN Gru A ITS HM Grw y TS MD Grut 1 i We SENA 1 Wide min limit amp User manual KS92 94 118 12 07 2000 Parameters 17 2 Set point function Text 1 Description Range Default Setrt Set point parameter LC Band width upper limit 0 9999 _ switched off LE Band width lower limit 0 9999 switched off WE lower set point limit for Weff 999 9999 0 Wine upper set point limit for Weff 999 9999 100 WE additional set point 999 9999 100 Grit set point gradient plus with W w min 0 01 99 99 _ switched off Gri set point gradient minus with W w min 0 01 99 99 switched off Grew set point gradient with W2 w min 0 01 99 99 switched off 17 3 Time function Text 1 Description Range imMer Timer parameters TS Start value Year 0 255 TS MD Start value Month and day Month 1 12 Day 1 31 TS HN Start value Hour and
96. d value pairs The segment points are interconnected by straight lines so that each input value xs corresponds to a defined output value ys Beyond the defined segments the first or the last segment is prolonged Adjustable parameters x1 y1 x2 y2 x8 y8 yx sei xs2 xs3 xs4 xs5 xs6 xs7 xs8 N Input values x values have to be set in ascending order 12 07 2000 37 User manual KS92 94 KS92 94 function survey 5 7 4 5 7 5 5 7 6 5 7 7 Signal output 4 OUT4 gt T 5501 Switching signal output OUT4 can be used for various signals This is a relay output Which signal shall be taken to this output must be determined at configuration level Selection of controller output Y 1 2 and alarm signals limit is possible One of the four programmer outputs 1 4 and programmer end is possible Direct or inverse motor actuator output action can be adjusted Signal output 5 OUTS 9 T 55 i Switching signal output OUTS can be used for various signals This is a relay output Which signal shall be taken to this output must be determined at configuration level Selection of controller output Y1 2 and alarm signals limit is possible One of the four programmer outputs 1 4 and programmer end is possible Direct or inverse motor actuator output action can be adjusted Digital outputs dol to do6 dol indicates the status of control output 1 with programmer do2 indicates the status of control output 2 with program
97. difference 999 9999 0 LIMZ Alarm 2 LimL Low limit 999 9999 _ switched off LimHZ High limit 999 9999 switched off Lxsd Switching difference 999 9999 0 CIMS Alarm 3 Limia Low limit 999 9999 gt switched off LimHa Bigh limit 999 9999 switched off Lxsds Switching difference 999 9999 0 LIM Alarm 4 LimL4 Low limit 999 9999 ___ switched off LimH4 High limit 999 9999 _ switched off Lxsd4 Switching difference 999 9999 0 17 6 Self tuning Text 1 Description R W Range Def UNE Optimization CF Correcting variable whilst process at rest R W 105 105 0 J Yort Step width during identification R W_5 100 100 F rt Parameter set to be optimized R W 0 3 1 Trial trigger point 1 set 10 set 2 R W 999 9999 Decimal point as configured in 130 ODF Tr ia2 trigger point 2 set2 set 3 R W 999 9999 Decimal point as configured in 130 ODP Tr i 33 trigger point 3 set3 set 4 R W 999 9999 Decimal point as configured in 107 ODP DR e 1 Self tuning result during heating 0 Cancellation during optimization preparation 1 Cancellation wrong output action 2 Finished successful optimization reversal point found 3 Cancellation process does not react or is too slow 4 Cancellation reversal point found estimation unsafe R 5 Cancell
98. e temperature limiting controller INP1 Z e g product temperature T Override control with three point stepping output Override control with three point stepping output can be realized in the same way by configuring a continuous controller with position control E 101 Override control is also possible using a classical three point stepping controller however option C is required for this limited controller The positioning signals of the limiting controller must be connected as shown in Fig 37 opposite Selection which of the two controllers is activated in the process is made by the logic of the slave controller The first CLOSED pulse coming from the limiting controller switches over to override control The limited controller will be re activated automatically when further closing of the motor is required for the first time Via additional analog output OUT3 option C the motor position can also be transmitted as a mA signal to and displayed on the master controller Fig 37 Override control with 3 point stepping controllers e g pressure limiting controller e g flow User manual KS92 94 54 12 07 2000 8 5 8 6 12 07 2000 Correcting variable processing Bumpless A M switch over Sudden process interventions by control mode switch over are usually not desired Exce
99. e actuator inertia and measurement of potentiometer via INP6 800ms the limits may be exceeded insignificantly Configuration Effective controller parameters L 100 CFuric 07 Three point stepping h neutral zone 0 2 999 9 controller without feedback Trulz Min pulse length 0 1 2 0 s 08 Three point stepping Tri Actuator travel time 10 9999 s controller with feedback WE additional correcting variable 105 105 Ymir min correcting variable limiting 105 105 Ymax max correcting variable limiting 105 105 Fl proportional band 1 0 1 999 9 Trl integral action time 0 9999 s Tul derivative action time 0 9999 s User manual KS92 94 70 12 07 2000 Optimizing the controller 11 2 6 Continuous controller 12 07 2000 The static characteristic corresponds to the one of the already described two point controller The continuous controller in split range operation is comparable to the three point controller The neutral zone can also be adjusted separately me yy Y ert Hlp 106 Fig 55 Lenger Static operating 20 p principle of vo continuous controller Kshl en 0 4 mA AP Xp Xp With a continuous controller with position feedback the actually flowing positioning current can be measured and displayed via INP6 Yp is not used either Maximum and minimum output current are adjustable y 0 100
100. e in the availability of all functions which are possible with continuous controllers such as override control working point adjustment adjustable correcting variable limits use of a disturbance at the positioning output Switch over to a second correcting value Y2 The disadvantage might be that the control availability depends on the Yp potentiometer which is subject to wear This fact is taken into account by automatic switch over to three point stepping control without position feed back in case of potentiometer error Fig 56 Continuous controller with position controller User manual KS92 94 Configuration Effective controller parameters E 88 Furic 09 continuous controller TFu1 5 min pulse lehgth 0 1 999 9 s with position controller Tra actuator travel time 10 9999 s AS hl neutral zone Xw gt 0 0 0 999 9 ssh neutral zone Xw lt 0 0 0 999 9 MZ additional correcting variable 105 105 Ymir min correcting variable limiting 105 105 WMA max correcting variable limiting 105 105 Fl proportional band 1 0 1 999 9 Tril integral action time 0 9999 s Tul derivative action time 0 9999 s 72 12 07 2000 Optimizing the controller Optimizing the controller 12 1 12 1 1 grad x 0 12 1 2 12 07 2000 Self tuning For determination of the optimum
101. e set point is adjusted in yeast e g w 3 The ratio inputs are scaled in equal units The control deviation is multiplied with s 0 01 and calculated according to equation xw x1 NO 0 03 x2 so that exactly 3 of yeast are batched with xw 0 Process value display is also in Constant No is without importance No 0 User manual KS92 94 50 12 07 2000 Process value calculation w x1 x1 x2 w x1 x1 x2 In this example water x1 must be batched as a percentage of the total paste x1 x2 an As the paste quantity is not available directly as a measurement signal the total is calculated internally from x1 and x2 x1 gt No 0 must also be adjusted in this case INP5 3 farina Fig 27 Ratio control x1 x1 x2 mr LIL Pn LUH Input 1 y WR Cp Display of material flow rates INP 5 3 10 kg h farina 100 kg h water X VW i W x2 x1 NO x1 Unlike the previous examples yoghurt x2 and the final product x1 are measured in this case w x2 x1 N0 x2 y joghurt Fig 28 Ratio control x2 x1 N0 x2 extended operating level Process value display mn ir HH weff A i wu LIL i arm INPS DUDU Input 5 Inn u INPi t Input 1 1 UU Display of material flow rates 80 kg h Joghurt NO INP 1 V h gt
102. e the signals reach output OUT3 they can be processed again by means of function block Func gt 1 565 Configuration parameter Func permits selection of direct signal output scaling and linearization With direct ee output the subsequently adjustable parameters X and X100 are not taken into account 578 andi 71 U Scaling A Scaling is adjustable according to reference values Xo 20 mA and X100 15 mA Example 1 10 mA This scaling is a simple allocation of 0 100 to 0 20 mA Se The output is determined for 0 20 mA Xo 0 X100 100 0 25 50 75 100 When applying value 50 the output is 10 mA Example 2 This scaling is an allocation of 0 200 to 0 20 mA The output is determined for 0 20 mA Xo 0 X100 200 5mA When applying value 50 the output is 5 mA X0 X100 Example 3 20 mA This scaling is an allocation of 10 110 to 0 20 mA whereby an offset is provided 18 mA The output is determined for 0 20 mA Xo 10 X100 110 Ki When applying value 50 the output is 8 mA Q CHAR Linearization O mA 35 50 60 85 110 X100 8 adjustable segment points value pairs xsi ysi can be used for simulation YA The number of value pairs is limited to 8 7 segments When using less than 8 value pairs Ys the first unused segment must be switched off by entry of the xs value into Offset and gradient for the relevant intervals are calculated automatically from the adjuste
103. ea eee X2in GE EE The difference between corrected values and input input values is equal over the complete range characteristic X1out lt Xlin gt Example 2 Gain change rotated around the coordinate origin corrected xlin 0 C xlout 0 C characteristic x2in 300 C x2out 300 C 1 5 C X2out ee X2in ae The corrected values are equal to the input values at input xlin and xlout but the difference increases characteristic X1out X1in Example 3 corrected Zero and gain matching characteristic s A o o O xlin 100 C xlout 100 C 2 0 C X2out Inne x2in 300 C x2out 300 C 1 5 C The corrected values are already different at input values E le input xlin and xlout and the difference increases additionally characteristic Xlout Xin User manual KS92 94 28 12 07 2000 KS92 94 function survey 5 5 Signal pre processing Input value conditioning is followed by signal pre processing The analog input signals can undergo further conditioning Fun TL and Furic are spacekeepers for configurable functions which can be selected from the following function library 12 07 2000 INP Funktion library CHAR Measurement II value Signal pre processing Each function can be used only once either in Func or in Func2 The table gives a survey of inputs and usable functions
104. ecimal point 04 Type S 0 1760 C Standard signals 3 3 digits behind decimal 05 Type RO 1760 C 30 0 20 mA point 06 Type T 0 400 C 31 4 20 mA 07 Type WO 2300 C 32 0 10 V only with type 20 40 08 Type E 0 900 C 33 2 10V 09 Type B 0 400 Potentiometric transducer 1820 C 40 0 500 Ohm x0 physical value at 0 numeric value 999 9999 select only with type 30 40 x100 physical value at 100 numeric value 999 9999 X0 X100 select only with type 30 40 1 Unit settings for scaling of Typ 00 26 With Typ 30 40 the value is fixed to 0 For this case the unit to be displayed will be configured by LHD i 103 User manual KS92 94 Configuration Additional configuration o Via the additional configuration the default setting for the signal input can be changed or matched O dependent of sensor type class STE AEorr Signal eG with sensor Temperature Process value correction enable ault compensation 1 upscale X100 0 not effective 0 not effective 2 downscale X0 1 internal TC 1 with process value correction adjustable via 3 XFail E 13 2 external TC TC fixed in parameters 11m 1004210420044 Le 0 Type 00 26 31 40 type 00 09 Non selectable digits are marked by 0 Tkref o external TC el numeric value 99 100 C or F select only with type 00 0
105. ehind decimal point Span start X0 only with ratio controller Xmin min process value limiting Xmin Numeric value 999 9999 Span end X100 only with ratio controller Xmax max process value limiting Xmax Numeric value 999 9999 and Xmin Xmax User manual KS92 94 100 12 07 2000 Configuration Factor for stoichiometric ratio s only with ratio controller o S stoichiometric ratio O Numeric value 00 00 99 99 2 fixed digits behind decimal point z actor Programmer configuration o only with programmer configured Frog Pur Ue PEnd PStrt Be ea Behaviour with mains recovery Behaviour with program end Source for Run Stop 0 program selection 0 continue program 0 continue with following 0 start stop and via operation 1 stop program and switch over program reset together D 1 program selection to Wint 1 following program and control with via control input 2 continue program after reset start required int ext without automatic research Option B 3 continue program after successful automatic research 1 start stop and otherwise switch over to Wint reset separate 4 continue program at the time mark of mains recovery Option B 16 5 SOURCE Input signal allocation Input signal allocation is dependent of main controller configuration E HDH this proposal must always be checked before commissioning and corrected if necessary Therefore input si
106. elf tuning grad x 0 Fig 58 Self tuning grad x lt 0 X lt a w we Ya Ya 1000 1009 Yortm 1 0 4 gt 0 1 E i gt adaption optimization adaption start optimization start finished finished Start during manual operation Self tuning start during manual operation can be done only if the controller was switched to manual mode via its front panel or via the interface During switch over to manual operation the correcting variable output last is stored as manual correcting variable When starting the self tuning this correcting variable is used and output as temporary stable correcting variable After reaching PiR the optimization is started Pre requisite for optimization start is a sufficient set point reserve gt page 73 Process at Rest PiR can be reached already when starting i e the waiting time is omitted As during automatic mode the set point can always be adjusted Fig 39 Start by increasing the setpoint Fig 60 x WA a _W Ka u A lt i gt Lo Ya 1007 i i 100 0 een gt gl gt Ed adaption optimization JE adaption optimization start finished start finished After successful self tuning switch over to automatic mode is automatic The process characteristics are available as parameters Tul Vmax1 The parameters for the required control behaviour are determined on the basis of these characteristics
107. ement variable x3 or the galvanically isolated external set point Wext or the override control signal ovc are configured with option p c b C fitted in the controller and the function selected during controller configuration The configuration words for INP4 are explained in section and see following table Main configuration apt see HN Optional configuration 1 Optional configuration 2 8 Linearization table i 16 6 4 Signal input 5 INPS ratio variable x2 ext set point Wext The signal for ratio variable x2 or external set point Wext is configured with option p c b not fitted in the controller and the function selected during controller configuration The configuration words for INP5 are explained in section and see following table Main configuration KI sce nara LTL D run L tuC additional 0 2 10V type 32 33 Additional configuration AL EY tf d Leen een en FAN ay IT oU sam TEL without linearization Func1 2 2 Optional configuration 1 D 16 6 5 Signal input 6 INP6 auxiliary variable Yp feedback Yp The signal for the auxiliary variable Yp or for the position feedbackk is configured if this was selected during controller configuration The configuration words for INP6 are explained in section and see following table Main configuration LHS0 see HR additional potentiometric transducer for Yp type 40 TUE I L I i Additional configuration f XFail
108. er are decisive For dismounting the controller module from the housing remove the captive screw on the controller front Hereby the module is released from the housing until it can be removed 2 1 2 Installing the controller in the housing LI Note that each specific controller module belongs to a particular housing Insert the module carefully into the housing guide rails in the correct mounting position and slip it in position without pressure A small remaining gap between front and frame is correct Tighten the screw on the controller front until the module is firmly locked in position User manual KS92 94 12 12 07 2000 Electrical connections Electrical connections TT The electrical connections must be made according to the connecting diagram For R F interference suppression the mains cables must be kept separate from all other cables L The protective earth which is to be taken to terminal A11 P13 with continuous controllers must be grounded via a lead which should be as short as possible 15 cm during test TI When connecting a contactor to the relay output an RC protective circuit is required to prevent high voltage peaks which might cause trouble to the controller The controller is provided with flat pin connectors 1 x 6 3 mm or 2 x 2 8 mm for electrical connection Connecting diagram galvanic isolation 24V PCBABA 10 ae le PETECE
109. es By using the tracking functions transition is bumpless Process value tracking after switch over the effective process value is stored as internal set point Set point tracking after switching over the external or program set point used so far is stored as internal set point Ratio control See section from page Particularly suitable for control of mixtures e g fuel air mixture for ideal or stoichiometric combustion For taking e g the atomizer air into account zero offset NO can be added X xw differentiation Dynamic changes of process value or set point affect control in various ways X differentiation for better control process value disturbance changes are used dynamically to improve control i e the controller disturbance behaviour is used Xw differentiation Process value disturbances and set point changes are used dynamically to improve the control result 1 e in this case the improvement is dependent of both disturbance and control behaviour 131 User manual KS92 94 Terminology explanation User manual KS92 94 132 12 07 2000 Index 12 07 2000 A Alarm processing Auto man switch over additional functions B Bandwidth monitoring Bumpless switch over Auto man y gt Y2 C Configuration Outputs Inputs Inputsignal allocation Controller Structure Continuous controller e Continuous controller with position control Control using a disturbance signal D Digital inputs
110. ess value x1 22 dWext 27 Alarm 3 Limit 3 e 03 controller output Ypid e 12 process value x2 23 Weff 28 Alarm 4 Limit 4 04 position feedback Yp 13 process value x3 24 Wp programmer With a controller with continuous output the output signal type can also be determined 0 20 mA 4 20 mA or logic signal 0 and 20 mA can be selected Direct or inverse motor actuator output action can be adjusted Signal output 2 OUT2 gt L 5 3 Switching signal output OUT2 is used for controller correcting variable Y1 Y2 This is a relay output Which signal should be taken to this output must be determined at configuration level Selection of controller output Y1 2 and alarm signals limit is possible Direct or inverse motor actuator output action User manual KS92 94 36 12 07 2000 KS92 94 function survey 5 7 3 Additional signal output 3 OUT3 optional CARD This output is only provided in conjunction with options p c b C Analog signal output OUT3 is used for a selectable controller signal As this is a universal output it can be configured for extensive functions Which signal shall be taken to this output must be determined at configuration level 1 550 Selection between various controller outputs process values and set points is possible Direct or inverse motor actuator action is selectable The output signal type can be determined Selectable are 0 20 mA 4 20 mA or logic signal 0 and 20 mA Befor
111. etrical on both sides of the set point The type of positioning signals is selectable e heating switching cooling switching e heating continuous cooling switching e heating switching cooling continuous Combination heating continuous and cooling continuous is covered by continuous split range With inverse controller output action heating is allocated to output OUT1 and cooling is allocated to output OUT2 As the controller versions provide only OUT1 with current signal heating switching cooling continuous seems to be possible only via OUT3 option C With direct action however cooling is allocated to OUTI and heating is allocated to OUT2 so that option C is not indispensable Configuration effective controller parameters L 00 CFuric 03 three point controller shi neutral zone Xw gt 0 0 0 999 9 Heating cooling switching Hh neutral zone Xw lt 0 0 0 999 9 04 three point controller heating YZ additional correcting variable 105 105 continuous cooling switching Ymir min correcting variable limiting 105 105 05 three point controller heating WMax max correcting variable limiting 105 105 switching cooling continuous vE working point of correcting variable 105 105 rl proportional band 1 0 1 999 9 FZ proportional band 2 0 1 999 9 Trl integral action time 0
112. evel several operations gt 7 2 and transition to parameter level Para Menu 2 is always selectable at parameter level selection of additional displays Mark return to parameter level Eric return to operating level Ex i t transition to configuration level Cont Menu 3 is always selectable at configuration level permitting the MORE area More return to configuration level Erid return to operating level without storage of the last changes Hui t or with storage of the changes Exit Fig 8 Parameter setting PSPS Y rs e Value adjustment is as follows parameter values configuration codes Fig 9 Example for a Fig 10 Example for combined data single parameter e g C Codes TE an L A AU DUTZ 2 E m Sisnaloutrut 2 LimHi Max Lim value P E DUTZ H ett Main Confis rowan Lal Dit 21 User manual KS92 94 Operation User manual KS92 94 22 12 07 2000 KS92 94 function survey KS92 9
113. ex User manual KS92 94 Index Tracking Process value tracking Set point tracking Triangle star off Two point controller U User defined texts in Text2 W W2 second set point Y Yp signal User manual KS92 94 134 12 07 2000 Subject to alterations without notice PMA Proze und Maschinen Automation GmbH Anden varies P OB 30 320 D34113 Kaa Germany HADIR a Sours r serve de toutes modifications Printed in Germany 9499 040 44811 0005 9499 040 44811
114. for keeping command of the operation KS92 is only provided with one program of the described length KS94 contains max 3 programs recipes with 20 segments Fig 64 Recipe selection Program 3 analog output Program 2 Program 1 73 19 20 analog output f Pcl y Preset Lar Run Start Stop 71819 wi 11 control output 1 3 d m Reset control output 2 control output 3 Program No control output 4 81 User manual KS92 94 Programmer Recipe selection Recipe selection can be done via front panel extended operating level Po serial interface or control inputs configuration 2 Max 3 programs KS94 are selectable via control inputs Modification of the recipe number PH with already running programmer does not lead to cancellation of the instantaneous recipe Only reset cancels the current recipe and leads to the start Wp0 of the new recipe Following program e Automatic transition to the next process phase or e Waiting for enable start signal The adjusted programs recipes can be selected manually or executed as a sequence automatically Parameter FHext indicates the number of the program to be used for continuation of the operation after completion of the previous program switched off FHext 7 1 Thus an overall process can be divided into max three section
115. fset can be additive e g reduced stand by set point or a factor e g O2 correction or split load Offset can be triggered by an external contact whereby the value is defined via an analog signal or via an adjustable parameter Additional control modes e Ratio control stoichiometric combustion mixing ratios additives batching e Three element control level control in a steam boiler e Mean value calculation from two process values Apart from a correcting function for the measurement signal 1t is possible to scale linearize or square root every input and output signal This enables the controller to be matched precisely to the application without any supplementary equipment For every day practice feed forward control has proved very useful to line out disturbances e g with steam generating plants For applications where several controllers act on a single actuator the output limiting function is recommended Alternatively preset output limits can be used This not only applies for continuous outputs but also for switching and three point stepping outputs motor control g User manual KS92 94 General hints 1 1 1 11 1 1 2 1 1 3 1 1 4 Technical data The technical data are given in data sheet no 9498 737 28333 Safety notes Following the enclosed safety instructions 9499 047 07101 is indispensable The insulation of the instrument conforms to EN 61 010 1 with pollution degree 2 overvolta
116. ge category HI operating voltage 300 V and protection class I Additional with horizontal installation a protection to prevent live part e g wire ends from dropping into the open housing of a withdrawn controller must be fitted Electromagnetic compatibility The instrument conforms to European Directive 89 336 EEC and will be provided with the CE marking The following European Generic Standards are met Emission EN 50081 2 and Immunity EN 50082 2 The unit is suitable for use in industrial areas in residential areas RF interference may occur The electromagnetic radiation can be reduced decisively by installing the unit in a grounded metal switch cabinet Maintenance Behaviour in case of trouble The controller needs no maintenance The rules to be followed in case of trouble are Check mains voltage frequency and correct connections check if all connections are correct check the correct funktion of the sensors and final elements check the configuration words for required functions and check the adjusted parameters for required operation If the controller still does not work properly after these checks shut down the controller and replace it Cleaning Housing and Front can be cleaned by means of a dry lint free cloth No use of solvents or cleansing agents Electrical connections L The electrical connections must be made according to the connecting diagram For R F interference suppression the mains cables must
117. gnal allocation SOURCE is no independent main item and considered as additional configuration of CONTR Signal allocation analog signals 5 HZ Sklext 5 dl E Signal source for X2 with ratio Signal source for Wext with Signal source for W with Signal source for and three element controller controller with external set point W controller with set point offset wauxiliary variable 0 X2 switched off 0 Wext switched off 0 dW switched off 0 z switched off 1 X2 of INPS 1 Wext of INP5 1 dW of INPS 1 zof INP3 2 X2 of INP3 2 Wext of INP6 2 dW of INP6 2 zof INP6 3 Wext of INP4 3 dW of INP4 3 zof INP4 1 190 Shli amp select the source for int ext switching 12 07 2000 101 User manual KS92 94 Configuration Allocation of digital signals for set point processing Shlie STrac Sdllon Sue he Set point switch over from Bumpless switch over to int set i 2 Switch over to internal to external point with int ext switch over ine SEE set point w2 0 only internal set point 0 no tracking 2 0 no offset 2 0 no W2 2 1 W Wext via front 1 tracking on 1 offset on 1 fixed to W2 2 dil external set point 2 di2 tracking on 2 dil offset on 2 dil W2 3 di2 external set point 3 dil2 tracking on 3 di2 offset on 3 di2 W2 4 dil internal set point 4 di2 tracking off 4 dill offset on 4 dil2 W2 5 di2 internal set point 5 dil2
118. gured for INP6 gt L S The position feedback must be calibrated This can be done in two steps for Xo or X100 e Calibration for Xo Select xElc as shown in Fig below Press the selector key the CG on the display xHc starts blinking Now bring the potentiometric transducer into the position for Xy usually lower end position The instantaneously valid value for INP6 appears on display 1 Press the selector key again to store this actual value as X0 e Calibration for X100 must be done accordingly Select 1 fic Press the selector key The 2 of the display x 1c starts blinking Now bring the transducer into the position for X100 usually upper end position The instantaneously valid value for INP6 is shown on display 1 Press the selector key again to store this actual value as X100 Fig 42 Selecting parameter HG x laz End a Sienl Ena Am Aux Input Contr Tune Man Limit Position feedback yP as a potentiometric transducer As a potentiometric transducer a potentiometer is connected mechanically to the potentiometer The potentiometer must be connected to the controller terminals Energization is via terminals 0 and 100 The voltage proportional to the motor actuator position is tapped via ter
119. he control parameters for the first time they must be adjusted as follows e Xp as high as possible to the highest adjustable value e Tyv relatively high max the time needed by the process until a clear process reaction starts e Tn high max the time needed by the process for the overall reaction The time requirement for empirical optimization is rather high In order to have a reasonable result within a relatively short period of time we recommend proceeding as described below Adjust Tn Tv 0 and Xp as high as possible P controller Reduce Xp from attempt to attempt as long as control is sufficiently stable If control becomes too unstable increase Xp slightly and continue with O Measure the permanent control deviation If it is sufficiently low self tuning is finished successfully P If it is too high PD control is better for the process adjust a relatively high Tv and continue with Reduce Xp from one attempt to the next one as long as control is sufficiently stable If control gets too unstable continue with Reduce Tv and find out if control can be re stabilized sufficiently If this is the case continue with otherwise increase Xp slightly and continue with Find out if Xp was reduced considerably during procedures 3 and amp If this is the case continue with otherwise PI control is recommendable for the process set Tv to 0 and continue with pg Measure the permanent co
120. he really relevant configurations is possible ENGINEERING TOOL ET KS 94 Engineering Tool ET KS94 permits realization of all operations which are possible via the KS94 front panel on a PC whereby controller configuration and parameter setting are facilitated considerably Configuration x Controller Dig inp Input Output Limit Option we E Engineering Tool ET KS9A Cory Controller function C100 Eile Edit MA Signaller with 1 output Signaller with 2 outputs DlEJE k Connection to controller pepinos p gi i Three point La Select Version pol i n g i Fi y Controller type Standard controller DER RESTER Three point heating continuous cooling switched E Three point heating switched cooling continuous a 2 s i Delta star off Es Setpoint functions Setpoint control x Three point stepping Zo Three point stepping with position feedback Yp S Continuous controller with 3 point output S 7 Additional configuration C101 Continuous controller e IEEE d y Continuous controller split range De Operating sense inverse Continuous controller with feedback Yp n SE Differentiation on process value X y On sensor break y min 0 Options gt Ratio control Program control Cancel Help The engineering tool offers the following functions L Creation and modification of the paramete
121. ignal inputs are available e process value x INP1 INP3 or INP4 e external set point We dWe INP5S e position feedback yp INP6 Signal input 1 INP1 main variable x1 gt 1 200 The analog input INP1 is used as main variable x1 The input sensor type can be determined as thermocouple resistance thermometer potentiometric transducer or as a standard signal The physical unit is freely selectable If required additional input configurations can be determined with the extra configuration C Thermocouple input The following thermocouple types are configurable as standard Type E J K L N R S T and W to IEC584 The signal behaviour can be affected by configuration of the following points Distinction of internal and external temperature compensation is made gt 205 e Internal temperature compensation The compensating lead must be taken up to the controller terminals Lead resistance adjustment is not required e External temperature compensation A separate cold junction reference with a fixed reference temperature must be used configurable between 0 and 100 C gt Ll 11 The compensating lead must be taken only up to the cold junction reference from which point copper lead must be used Lead resistance adjustment is not necessary e Upscale set point lt lt process value or downscale set point gt gt process value action of the built in TC monitoring can be configured or a fixed substitute value can be use
122. il di2 OR after selecting manual operation via front panel key Contrary automatic Cascade control Particularly suitable for temperature control of e g steam boilers A continuous master controller load controller provides its output signal as an external set point to the cascade controller which alters the correcting variable Override control OVC See section from page Limitation of the smallest OVC or of the highest OVC correcting variable to the value of an analog input This limitation control can be used e g if control shall be continued by another controller after reaching defined process conditions Transition from unlimited r limited correcting variable and vice versa are bumpless 129 User manual KS92 94 Terminology explanation Program control See section from page The effective set point follows the programmer profile For this the controller must have been switched to Wext Process at rest See section from page For a clear self tuning attempt the control variable must be at rest Various rest conditions can be selected Ramp function See section from page Set point changes are in ramps instead of stepwise See gradient control Rapid Recovery See section 9 2 from page 59 The controller knows its working point it can start with the right correcting variable for this working point i e it will return to its working point much earlier Control parameters See section from page For
123. int is 1 determined by internal set point W however it can be affected by u external offset dW The type of offset additive or factor is determined during configuration 76 by parameter dl x The offset is switched on via signal source Shar determined in configuration parameter 190 41 User manual KS92 94 Set point functions U Set point cascade with internal offset WFunc 4 With set point cascade control with internal offset switching over between internal set point W and external set point We is possible Switching over is done via signal source Sli ve determined in configuration parameter E 31 External set point We can be affected by an internal offset dW The x offset type additive or factor is determined during configuration L 06 by parameter ON The offset is switched on via signal source Glddop determined in configuration parameter E 41 U Set point cascade with external offset WFunc 5 Set point cascade with external offset permits switch over between internal set point W and external set point We Switch over is via signal source Shi ve determined in configuration parameter 190 dwe External set point We can be affected by an external offset dWe The offset type additive or factor is determined during configuration E 86 by parameter dhl The offset is switched on via signal source Silor determined in configuration parameter E 4H U Programmer with internal offset WFunc
124. internal reference 248 A voltage INP3 200 ms C INP4 200 ms E INP5 800 ms A INP6 400 ms A OUT 1 2 4 5 100 ms P OUT3 100 ms C di3 7 100 ms B di8 12 100 ms C dol 4 100 ms B do5 6 100 ms C Linearization error Thermocouples and Pt100 are linearized within nearly the overall physical measuring range Linearization is with up to 28 segments which are placed in the error curve optimally to compensate the linearity errors As the error curve approximation is only by polygons and not by an nth order polynomial the remaining error is zero in some points of the characteristic curve Between these zero points however there is a very low though measurable remaining error For reproducibility however this error is not relevant because it would be reproduced in exactly the same point if the measurement would be repeated under identical conditions Temperature compensation Measurement of the cold junction reference temperature with thermocouples is using a PTC resistor The temperature error thus determined is converted into mV of the relevant thermocouple type linearized and added to the measurement value as correcting value with correct polarity The remaining error with varying cold junction reference temperature is approx 0 5K 10K i e about one twentieth of the error which would occur without compensation Better results are possible with a controlled external TC which is adjustable within 99 100 C dependent of te
125. isolation and do not cause potential compensation The same applies to control outputs do which are connected electrically with control units 1 e which imply a risk of potential connections In the connecting diagram on page 13 the double lines clearly show the galvanic isolations throughout the controller Galvanic isolation of inputs and outputs is shown in the following drawing KS94 i 4 w4 OUT3 eee DA Process value 7 Process value ines OUTI y 2 a L J o ik y1 JE x P Corr value Set point u EZ y3 er L y5 pots 25 User manual KS92 94 KS92 94 function survey 5 4 5 4 1 5 4 2 5 4 3 Input conditioning Before the pre filtered time constant limiting frequency analog input signals are available as digitized measurement values with physical unit and can be used e g as process value set point or position feedback they undergo extensive conditioning X100 0 5 9999s i Amplifier Sensor Lineari Skaling Filter Mesurement i monitoring zation value i i correction i i a loge a Measurement INP PEL A zZ value foes 7 SIT aa Measurement value processing Input circuit monitor Thermocouples The input circuit monitor provides thermocouple checking for break and wrong polarity An error is found if the value of the measured thermovoltage is by more than 30 K below the span start Pt100 measurements and potentiometric
126. ital inputs die sido eK RE OS AER 15 3 5 Digital outputs del to do6 O ase wae How ek HE God EW Ae ek ake HS 16 3 6 Versions with integrated supply voltage ss cs su Ka EE a sa an 16 3 7 Connecting the bus mtettace D e 4 au cidad oe ee A A 17 3 7 1 A AI 17 3 7 2 Remote local ssas ka skeen ion dra 17 3 73 Connection examples s sag eae aa Ee Re RR 18 a Operation sasise EE a a REA A HSE Se GS ae 19 Al Front VIEW a sia ek er Ek OG RES e RS ee ee A A A SK MR oa 19 4 2 Status displays se sect ba og eB of ea Se Gok oe oe aie ee oO ee 19 43 Ments Las ee erin e a ee Bw A ee Me we ee wee Ge weh ee 20 4 4 Ihe operating level ss s isos por Ale ee ee oe wee A a ee 20 4 5 Parameter and configuration level 24 2 5454 Kar Seiser EH ES 21 KS92 94 function survey een ernennen 23 5 1 Basic Watdware functi nsSs s os sua a a Be a Yo A a De 23 dll Girc it board Po pta da BR a A A dg 23 5 1 2 Circuit board e ang ds wie a en Dekan 23 Ss Circuit board B optional we ENT ae owe a ANE e Eer de 23 5 1 4 Circuit board C optional only possible with KS94 23 5 2 Survey of included function modales y ie oe Caw Ke ow He iE ee OR ie 24 5 3 Galvanic isolation oo oo on 25 5 4 5 5 5 6 37 Tasten HINA AR ran ie Fra 26 5 4 1 Thput circuit MONTOS rra As A 26 5 4 2 SAO eds de Gd Sen ee ects Seah Ge Has Re Ge ee ee See Sa 26 5 4 3 ageet ae ad we He Aw E OE ww we a dE 26 5 4 4 Additional measurements A arras
127. itch over L t30 Sw W2 signal source for weff W2 set point switch over cag SWdon set point offset switch on IK S Wd signal source for set point offset LAD Wd set point offset type CLDR SWext signal source for external set point Lian WTrac tracking function switch on LYDE STrac signal source for tracking LC 490 WSel automatically selected lowest or highest set point COB General The following set point functions are selectable during configuration C 100 using parameter WFunc In addition to the described effective set points switching over to the second set point W2 is possible Switch over is via signal source Sw W2 determined in configuration parameter C 190 LI Set point WFunc 0 With set point control the set point is determined by internal set point W Set point cascade WFunc 1 gt INP 5 6 4 With set point cascade control switching over between internal ig set point W and external set point We is possible Switching over is done via signal source GN ve determined in configuration parameter Tian Lit KI U Programmer WFunc 2 With programmer control the set point is determined by the internal programmer Wp Switching over to the internal set point W is possible and must be done via the signal source GL e determined in configuration parameter 90 Set point with external offset WFunc 3 INP 5 6 4 With set point control with external offset the effective set po
128. ith OC ont r 1 4 5 7 KS 94 switches over Set 1 automatically between the max 4 parameter sets The switch over points are pre determined via adjustable Set 0 trigger points Parameter Dx sd determines the hysteresis for all three switch over functions e REE Ek Jessen Fig 62 Switching over parameter sets via controller signals Oxsd e Buy Zur Bul Joss gt X W Y XW Switch over via Description 0 no function only the actual parameter set is effective control disturbance behaviour parameter set 0 with control behaviour parameter set 1 with disturbance behaviour Disturbance behaviour is detected when the absolute value of control deviation xw is lt Trigl Self tuning can determine only parameter set 0 for control behaviour 2 Operation Switch over is by changing parameter ParNr Contr gt CPara ParNr In order to reach the parameter quickly the parameter should be at extended operating level gt section 4 4 page 20 3 Control inputs Switch over is via digital inputs di8 and di9 on options card C Which parameter set is active with which input allocation is shown in the table opposite parameter di8 0 1 0 1 di9 010 111 Parameter 0 1 2 3 Set point weff Switch over is at adjustable trigger points of the set point signal see Fig 62 Process value Xeff Switch over is at adjustable trigger points
129. juaw Gpejmouyoy a gt e node 8 finde a esoe E DEEI 11603 uoljisod gt p Em H IER sinos Indu pue anjea indu wey nuau yo uonejas 10 Ady E EI ZoR eS TOPs E DMR TORS Ae 10199 9S gt pH cope hey Gopd i 911815 8 9 OUZL DREI Our pueBa7 911918 ZL 6 9UZL 256567 22421 8sapog ms EBEI TPaMS z sepoJ MS h667 2P95 PU Is 96 User manual KS92 94 Configuration Fig 76 Survey of configuration
130. l supply The min max selection can be activated also with set point functions varying from those shown below Fig 22 Min Max selection with internal offset Fig 23 Min Max selection with external offset INP 5 T INP 5 bg we we gt BO A aa dWon dwe Wsel Wsel x x User manual KS92 94 48 12 07 2000 Process value calculation 7 1 7 2 7 2 1 7 2 2 12 07 2000 Process value calculation Fig 24 Standard conroller Standard controller The process variable measured via analog input INP1 weff and processed if necessary using functions Func1 and Func2 is used as process value x by the ea a controller x X W Ratio controller Process control frequently requires various components to be mixed into a product These components must be mixed according to a given ratio The main component is measured and used as reference for the other components With increasing flow of the main component the flow of the other components will increase accordingly This means that process value x used by the controller is determined by the ratio of two input variables instead of being measured as one process variable For optimum combustion the fuel air ratio must be controlled With stoichiometric combustion the ratio is selected so that there are no residues in the waste gas In this case the relative instead of the physical ratio is displayed as process value and adjusted
131. lable any more Therefore the programmer is reset in this case The controller uses set point Wp Wp0 and waits for further control commands e Start via contact or operation system menu serial interface o Preset 13 6 2 Memory RAM available The behaviour is configurable E 124 Fur ar Pur Behaviour H The program is continued at the point of failure Fig 73 c Starting from the instantaneous process value the effective set point runs towards the program set point with the relevant gradient Grw The programmer continues running as long as bandwidth monitoring does not respond 1 The programmer goes to manual mode Fig 73 b Despite applied control signals the process value is stored as internal set point W with X tracking configured and the programmer waits for operator intervention The program continues running Without tracking the internal set point is effective z Automatic search mode in the actual segment and program continuation Fig 73 a For unsuccessful search mode see chapter A Automatic search mode in the actual segment Fig 73 a With unsuccessful search mode the programmer goes to manual mode Fig 73 b and the process value is stored as internal set point W with X tracking configured Without tracking 4 Program continuation in the segment in which the programmer would have been without power failure This function requires the KS9x real time clock Searching Fig 73 a
132. lling is via output OUTI if this was determined as Src 27 by configuring 580 10 4 Alarm 4 limit 4 The function of this alarm is determined in configuration parameter L A D Alarm signalling is via output OUT2 if Src 28 was determined by configuring 5 30 User manual KS92 94 64 12 07 2000 Optimizing the controller Optimizing the controller 11 1 11 2 12 07 2000 Process characteristics In order to tune the controller to the process the process characteristics must be determined During self tuning these process data are determined automatically by the controller and converted into control parameters In exceptional cases however manual determination of these process data may be necessary For this the response of process variable x after a step change of correcting variable y can be used see Fig 48 Usually it is not possible to plot the complete response curve 0 to 100 as the process must be kept within certain limits The maximum rate of increase Vmax can be determined from the values Tg and Xmax step from 0 to 100 or tand x partial step response Fig 48 Step response of process y correcting variable YA 100 Yn control range Yh Tu delay time s 0 2 Tg recovery time s t Ka XA Tg i Vmax Xmax Tg Ax At max rate of increase of process value 1 AX Xmax Maximum process value X i At Xn adjustment range of controller x1 HA x4 e
133. me are displayed on the front panel display 2 in hours minutes extended operating level page 88 Times above 99h 59min are rounded off and displayed in full hours minutes are omitted Times which refer to the past LBrut tHet are rounded off to the next lower full hour Times which refer to the future test gt are rounded off to the next higher full hour Rest time tFRest 6645 66 h 45 min Limit values alarm 1 4 can act also on program time LBr ut tHet or on rest time LRest Time related limit values are adjusted dependent of configuration C A DD ff PF either with four digits in full hours eg Di32 132h 0r with 2 digits and two digits behind the decimal point e g 5675 66h 45min Fig 65 Programmer time signification Program 1 i Program 2 Letz E Run gt lt tHet Run gt Run 1 Run Stop LBrut Run 2 Stop Run Stop Reset actual time Flat ramps The algorithm for determination of the increments with ramp shaped change mode within a segment is designed so that low set point changes with high set points can be realized also with high segment time e g crystal growing from ti 600 C to tit 612 C in 600h Programs recipes Number of selectable programs The required program recipe can be selected differently program number FM e front panel operation e serial interface e control inputs di6 di7 Due to the limited number od displays and
134. mer do3 indicates the status of control output 3 with programmer do4 indicates the status of control output 4 with programmer do5 indicates if the controller is in manual or automatic mode or the yl condition with switching controllers 5 FE do6 indicates if the controller uses the external or the internal set point or status y2 with switching controllers 59 1 Input and output survey U allocation of analog inputs outputs and circuit boards circuit board EN circuit board A C option p P C option process inputs INP1 x OUTI INP3 OUT2 INP4 OUT3 INP5 x OUT4 INP6 x OUTS xx xx xx circuit board circuit board i i B option C option control inputs control outputs dil dol xX di2 do2 x di3 do3 x x xx x di4 x do4 di5 xX do5 x x xx di6 do6 di7 di8 di9 dil0 dil1 dil2 Ss User manual KS92 94 38 12 07 2000 KS92 94 function survey Function allocation of analog inputs Ext Ext set point Auxiliar Position Min Max 31829 set point Se variable feedback Ove selection INP1 X INP3 x x x INP4 Xx X x x x INP5 x x x INP6 x x x x U Function allocation of control inputs Functions dil di2_ di3 di4 di5 di6 di7_ di8 di9 dil0 dill dil2 Wint Wext XxX Xx Tracking on off x x AW on off X x
135. meter level by pressing key gt 3s End return to parameter level Mark mark the selected parameter for display at extended configuration level Parameter Exit return to operating level level Conf transition to configuration level Allocation of parameters to the extended operating level Up to 12 parameters can be allocated to the extended operating level see Fig 77 whereby the controller operation is simplified since changing over to parameter level whenever one of these parameters must be changed is omitted Fig 77 Marking a parameter EN 2 ae x Allocation select required parameter press selection NE gt key G during gt 3s Para blinks Select Mark with up key Lal and acknowledge with selection key O see Fig Delete select the required parameter at the extended operating level press selection key CO during gt 3s Fara blinks and acknowledge with up key A Select Clear and acknowledge with selection key Fig 78 Deleting a parameter see Fig Extended oper level Hold The Hold function can be used for selecting a parameter from the extended operating level for being visible continuously For this select the required parameter at the extended operating level press selection
136. min current y2 y 10 max current The working point is adjustable yo 0 100 In order to operate the instrument as a P or PD controller T can be set by means of contact FB or by setting T 0 For optimizing according to the control response the hints given in Fig 8 must be followed With contact FB closed manual automatic and automatic manual switch over is bumpless Transition to the new correcting variable is with the adjusted integral action time Ty Configuration Effective controller parameters 2 100 CFuric 10 continuous controller Hh 1 neutral zone Xw gt 0 0 0 999 9 SAZ neutral zone Xw lt 0 0 0 999 9 11 continuous controller Z additional correcting variable 105 105 Split range Ymir min correcting variable limiting 105 105 12 continuous controller M1 max correcting variable limiting 105 105 with Yp feedback HF 1 proportional band 1 0 1 999 9 FZ proportional band 2 0 1 999 9 Tril integral action time 0 9999 s Tut derivative action time 0 9999 s 71 User manual KS92 94 Optimizing the controller 11 2 7 Continuous controller with position control This is basically a cascade A tracking controller with three point stepping behaviour which operates with Yp as process value INP6 is used with the continuous controller The advantages of this combination ar
137. minal yp Resistance Rtotal inclusive of lead resistances must not exceed Ik Position feedback yP as a 0 4 20 mA standard current signal The input resistance is 50 User manual KS92 94 56 12 07 2000 Special Functions 9 Special Functions 9 1 9 1 1 12 07 2000 Control using a disturbance signal Control with measurable disturbances z is used to improve the dynamic behaviour of slow processes with long delay times It is configurable C105 and can act either on the controlled process value or directly on the correcting variable without consideration of the control behaviour Option C INP 3 is required The pre processed disturbance variable Funcl Func2 can be used directly or after differentiation parameter Taz whereby either both output actions or only one are taken into account Fig 43 Set point W lt working point Yo p l process value X gt gt correcting variable Y CaS auxiliary variable z P roca POOG Yp signal According to the latest standard of information there are two reasons for using the position feedback control with three point stepping output In some installations the controlled process value must be lowered by several percent with increasing load The reduction is identical with a permissible tolerance Furthermore advantages may be gained mainly in slow processes with long delay time avoidance or reduction of
138. minutes Hour 0 23 Minutes 0 59 TE Final value Year 0 255 TE MD Final value Month and day Month 1 12 Day 1 31 TE HN Final value Hour and minutes Hour 0 23 Minutes 0 59 17 4 Programmer functions Fecri Programmer recipe 1 Analog Digital Text 1 Description Range Def Text 1 Description Range Def Mode Change mode 0 Ramp 0 A Reset value control output 1 4 0000 1111 10000 1 Step Tdi Time segment 1 0 9999 min 2 Ramp Time priority Ci control output 1 4 for segm 1 0000 1111 0000 Frac Preset mode 0 Segment start 1 Td2ZH Time segment 20 0 9999 min 1 Program time EZE control output 1 4 forsegm 20 0000 1111 0000 Fri xt Successive program 1 3 or 4 gt LC Band width lower limit 0 9999 L Band width upper limit 0 9999 WIFE Reset value WO 999 9999 0 TF1 Time segment 0 9999 min LPI Set point segment 1 999 9999 0 TFZE Time segment 20 0 9999 min E 3 WIFE Set point segment 20 999 9999 0 RecPz see programmer recipe 1 Feces see programmer recipe 1 12 07 2000 119 User manual KS92 94 Parameters 17 5 Alarm function Text 1 Description Range Default Alarm 1 LimLi Low limit 999 9999 ___ switched off LimH1i High limit 999 9999 _ switched off Led Switching
139. mperature adjusted at the cold junction reference With comparative measurements for assessment of the reproducibility however constant environmental conditions are indispensable when working with internal TC A draft at the PTC resistor of the cold junction reference can be sufficient to produce a measurement error 27 User manual KS92 94 KS92 94 function survey 5 4 9 Measurement value correction optional The measurement value correction can be used for correcting the measurement Prerequisite Configuration word 205 Kar r 1 page 104 In most case the relative accuracy and reproducibility rather than the absolute one is of interest e g measurement error compensation in a working point set point control minimization of linerarity errors in a limited working range variable set point conformity with other measuring equipment recorders indicators PLCs compensation of the sensor transmitter etc stray errors The optional measurement value correction can be designed both for zero correction and gain matching It corresponds to a scaling mx b with the difference that the controller firmware calculates the gain m and the zero offset b from the pre defined values for process value x lin x2in and set point x lout x2out of two reference points Example 1 Zero offset xlin 100 C xlout 100 C 1 5 C corrected characteristic gt x2in 300 C x2out 300 C 1 5 C A
140. n and inverse the normally closed operating principle The controller output action is inverse as usual e g heating or direct e g cooling Thereby correcting variable display and increment decrement keys correspond to the actual energy or mass flow direction Fig 39 Normal heating process process value l Fig 40 Normal cooling process process 4 cooling energy process value process N cooling energy 55 User manual KS92 94 Correcting variable processing 8 7 8 8 8 9 Fig 41 Heating process with inverting actuator process value variable inverted process Z cooling lt energy Positioning output switch off The controller positioning outputs can be switched off as a reaction to sensor error via control input and by the timer of the real time clock configurable Controller output action with sensor break Dependent of configuration sensor break causes 18 1 positioning output switch off output of the lowest correcting value output of the highest correcting value output of the second correcting value Y2 Position feedback Yp The position feedback can be used for detection of the position e g of the motor actuator or of the valve Position feedback Yp can be connected either as a potentiometric transducer or as a 0 4 20 mA standard current signal Analog input Yp can be confi
141. nd Ymax determine the limits of the correcting variable range within 0 100 With three point and continuous controller split range the correcting variable limits are within 100 100 The minimum separation of Ymin and Ymax is one digit Fixed correcting variable limits are specified with parameters ymin and ymax Fig 33 Fixed positioning limits i gc S D ch D We Goal Ac Ymin IRB ur 0 7 i 53 User manual KS92 94 Correcting variable processing 8 3 8 4 8 4 1 8 4 2 External correcting variable limiting override control Either the lowest OVC or the highest correcting value OVC can be limited by an external current signal INP4 E 105 Override control is used where bumpless switch over to another controller when reaching defined process conditions mainly according to other criteria is required The basic principle is that two controllers act on the same motor actuator Fig 34 Maximum value limiting Fig 35 Minimum value limiting Ymi 0 Override control Override control with continuous output Limiting control with three point stepping output is possible by configuring a continuous controller with position control gt section page 71 and by limiting the correcting variable via INP4 gt section 8 3 For this option card C is required Fig 36 Override control with continuous output e g furnac
142. nfiguration parameters and possible control operations Fig 13 Set point control E 00 WFung 4 mes Fon lt 1 lt I o y oe in MAX 0 WSel 2 INP3 pe 4 MIN W2 gt Fig 14 Setpoint cascade control or programmer 100 Nun or ei ET amp Y L we p Grw2 w A INP3 S wen i Geng W2 gt 12 07 2000 43 User manual KS92 94 Set point functions Fig 15 Set point control with external offset T 100 Mun 3 E 40 dWon gt off 0 INP5 INP6 INP4 IN gt WSel A E W2 gt AA X w gt W2 Fig 16 Setpoint cascade control with offset E 00 WFunc 4 4 a OM Y Operati 0 I 0 E DE ion Xx Pe Wi 0 l Wi gt 1 an E r Kine Sal max k A op gt gt MIN Po WIN RT WSel E User manual KS92 94 44 12 07 2000 Set point functions Fig 17 Programmer with ext or int offset C 144 WFune 8 7 ei E 95 ron poi Size 8 S vi 0 Operation 0b ery 0 gt ID 1 gt dil gt
143. nt can be configured gt 381 For input value processing a filter time constant with a numeric value within 0 5 and 999 9 is adjustable gt L 3 14 For configuration proceed in the following order C388 50 390 030 2 LI0E E3 13 03 13 Additional signal input 4 INP4 optional gt 3510 This signal input is only available with option p c b C fitted It can be configured for three element control x3 external set point or external set point offset gt E 817 Selection of 0 20 mA and 4 20 mA standard input signals is possible The physical unit can be configured The input resistance is 50 Q For the 4 20 mA standard signal the output action with sensor break can be determined gt 355 and 36 3 A physical input scaling is possible by determination of 0 and 100 9 35 and 352 Moreover the decimal point i e the digits behind the decimal point can be configured 3 3517 For input value processing a filter time constant with a numeric value within 0 5 and 999 9 can be adjusted 3 E464 For configuration proceed in the following order LISE CiS i 0952 0955 L36b3 L3bM Signal input 5 INP5 ratio variable x2 ext set point Wext gt THAD Analog input INPS is used for connection of the signal for ratio variable x2 or for the external set point Wext if option p c b is not fitted in the controller and with the function selected during controller configuration Selection
144. ntrol deviation If it is sufficiently low self tuning is completed successfully PD If it is too high PID control is preferable for the process stop changing Xp and Tv and continue with O Adjust a high Tn value and reduce it as long as control is sufficiently stable If control gets too instable increase Xp slightly and self tuning is completed successfully PID or PI Empirical optimization is improved considerably by using a recorder or engineering tool trend function for control variable process value X related to time requirement and quality and evaluation of the test results is facilitated significantly The method descibed above can be generalized only with restrictions and does not lead to a clear improvement of the control behaviour with all processes Changing working point Y0 trigger point separation Xsh and cycle times Tp1 and Tp2 leads to results which may or may not be satisfactory With 3 point stepping controllers Tm must be set to the real travel time of the connected motor actuator 77 User manual KS92 94 Optimizing the controller 12 3 Selectable adaptation only KS94 For certain applications matching the control parameter set to the actual process status may be reasonable For A gt this KS94 is provided with max 4 control parameter Set 3 sets which can be selected via various signals With default configuration only one parameter set is Set 2 available 100 0Cnte D bremen W
145. o RS422 RS485 is required 4 units may be connected to an interface module Operation KS94 data can be read or displayed and modified from the front panel PC interface or via the serial interface After delivery of controller KS94 the PC interface is active KS94 configuration and parameter setting are supposed to be done by means of the engineering tool before commissioning Switch over to the serial interface is either e via operator dialogue front press gt during 3 sec gt Fara flashes display dh t interf press a until CEs flashes A confirm briefly CBus A ee eae press gt during 3 sec gt Fara flashes display e press 4 until CFrrit flashes gt Kl confirm briefly CFrnt 2 switch over to front panel interface e or by activating REMOTE gt page 17 Switching back to LOCAL does not cause switch over to the front panel interface Switch over to the PC interface is only possible with the R L input set to LOCAL Remote local Units with serial interface are fitted with a hardware input di3 for switch over between REMOTE and LOCAL operation R L L During REMOTE all operations via the serial interface writing and reading are permissible The following operations are still possible via the keys of the local operating front panel LU Display switch over Display of parameters without modification
146. of the following modes can be selected par time counter process at rest Reset of monitoring Process at rest is detected when x is constant grad x lt 0 const amp inverse Process at rest is detected when x decreases regularly with a controller with inverse action grad x gt 0 const amp direct Process at rest is detected when x increases regularly with a controller with direct action grad x 0 Process at rest is detected when x varies regularly In this case continuation of this constant change as long as identification lasts must be ensured Set point reserve As a pre requisite for realization of the self tuning procedure the separation of set point and process value must be higher than 10 of WO W100 before output of the correcting variable step The set point reserve is realized either automatically by reduction of the correcting variable during the PiR phase or by manual set point or process value changing manual mode 73 User manual KS92 94 Optimizing the controller 12 1 3 12 1 4 Start during automatic operation After self tuning start stable correcting variable opt is output After detection of process at rest PiR the correcting variable step HWOFt is output and the parameter determination procedure is realized The set point can always be changed whereby the gradient function for set point adjustment is switched off Fig 57 S
147. of the input signal is calculated and the result is multiplied by parameter gain OUT gain root INP If the value under the root is negative the result is set to 0 Adjustable parameter for each input gain Filter The input value is taken to the output with delay The delay is according to a 1st order e function 1st order low pass with the filter time adjustable with parameter Tf Adjustable parameter Tf filter time 30 12 07 2000 A 5 12 07 2 A 56 14 ee 15 0 1 199 6 1 000 KS92 94 function survey Inputs The input names and numbers were selected for utmost language independent international clarity of the inputs and outputs on the process value display 7 segments during configuration Digital inputs and output are marked with lower case letters to permit clear distinction of 0 and o on the display IHFUT analog inputs The signal inputs for the previously selected controller configuration are determined in this main group The signal inputs for the selected controller function are displayed in the configuration menu As with control function configuration a large number of applications can be covered by determination of the main configuration Special cases can be matched and adjusted by additional option configuration at the second level INP2 is not available with controllers KS92 42 Therefore there is a gap in the input sequence Max the following five s
148. ogrammer runs di4 1 and is stopped at di4 0 Operating mode internal external remains unchanged 83 User manual KS92 94 Programmer Fig 69 Profile with stop at end position Preparation Operation for operation Process nun RESET RESET Program run program time Program START END Fig 70 Profile with automatic reset at program end Operation Operation Preparation Preparation for operation for operation Process valuex y ba Process value x H Dese eeh wun gt E ser Ae N ee TI Unser i U RESET pay fun program ame dupe ser GE 13 1 9 Control signals and status messages Control signals reset stop can be entered via control inputs static or via serial interface or via the front panel system menu dynamic edge triggered with equal priority Run start is required with program end with reset If necessary control input run start must be switched off and on again The programmer stores the last status of control commands capacitor buffered RAM so that operation from several points is generally possible Control signal priority Priority Description Status 1 Reset 1 0 0 0 2 Preset 0 1 1 0 0 3 Stop 0 1 0 1 1 0 Result Reset Preset Stop Run 0 1 any status 13 1 10 Pre requisites For the following descriptions of the operating principle the following setpoint related pre req
149. ome of these parameters are directly adjustable als A parameter can be displayed continuously with the Hold function Press J The extension can be left with Exit and Al or after a timeout of 60 s or with 2 O lt 3s Select parameter press A Y gt gt 3s gt Select Ha 1 d Press A w gt With the other operating mode is also selected If the set point is set to by means of Y the controller is switched off Menu 1 is always selectable at operating level deletion of additional display Clear communication interface switch over CBus CFrnt and starting 15t ar or stopping OSt0F the self tuning setting the clock Clack operate the programmer FRur e PStor FRes Poet and transition to parameter level P ar a eter level Para Fig 7 Operation Lu Aa A X mu Man Vv RD aq 30 30 A O de suo ll Poe Sollwert Feselabweichuns Wei2 3 Run Loo gt 3s Menuel 20 12 07 2000 4 5 12 07 2000 Operation Parameter and configuration level Menu 1 is always selectable at operating l
150. ons with integrated supply voltage The supply voltage can be used only for energization of a 2 wire transmitter or for energization of max 4 control inputs The supply voltage is potential free and can also be used for energizing inputs INP3 INP6 or for other units Selection of supply voltage or digital inputs is by S LL switches see figure opposite Transmitter supply voltage Digital input O Position T Position D open closed D closed T open The supply voltage is only applied to terminals A12 and A14 with INP1 configured for current or thermocouple E Z 00 Lopei and the S I L switches set for Connection of a 2 wire transmitter transmitter supply factory setting With the S LL switches setto on example of INPI or INPS digital input the voltage is applied to terminals Al and A4 Al independent of the configuration of input INP1 In this case the 2 voltage input of INP5 is not available 3 4 I Supply voltage for energization of External use of the 5 digital input e g dil di4 supply voltage l INP5 6 1 7 8 A B A i 1 1 12 gt di a 10 2 ear Mes 11 KE di3 14 gt e S dal_ 42 15 En ll fr a ae a INP 16 1 15 d 16 User manual KS92 94 16 12 07 2000 3 7 3 7 1 12 07 2000 Electrical connections Connecting the bus interface TTL or RS422 or RS485 PROFIBUS or INTERBUS With TTL an interface module for conversion t
151. optimum function the controller must be matched to the process dynamics The effective parameters are Xp1 Tin Tv and amp Dependent of controller operating principle the following parameters can be added T with 2 point 3 point controllers XP and TP with 3 point controllers X SF and Tpul 5 and Tm with 3 point stepping controllers Control behaviour See section from page In general quick line out to the set point without overshoot is an advantage Dependent of process various control behaviour types are required U Easily controllable processes k lt 10 can be controlled using PD controllers U processes with k 10 22 can be controlled with PID controllers O and difficult processes k gt 22 can be controlled with PI controllers Controller OFF With the controller switched off the switching outputs do not deliver any pulses and the continuous outputs are 0 Self tuning See section from page For optimum operation the controller must be matched to the process requirements The time required for this can be reduced considerably whereby the controller uses the process characteristics to determine the control parameters for quick line out the set point without overshoot Soft manual Normal manual operation during transition from automatic r manual the last correcting variable remains active and can be adjusted via keys A w The transitions from automatic gt manual and vice versa are bumpless
152. oring is possible for defective motor faulty phase sequence defective motor capacitor faulty rotary direction defective power transmission to spindle or gearing excessive backlash due to wear jammed control valve due to e g foreign bodies The function can be enabled via parameter DAC DAC 0 noDAC 1 DAC function checking U Description Unless correct Yp change detection is possible despite the output of closing or opening pulses there is a trouble The trouble is displayed and the controller goes to manual operation i e no pulses are output any more Display Signification Possible causes Block No reaction blocking e Cable break CirEr No reaction e Defective motor e capacitorPhase error e Wrong polarity Inn Controller output action error HD Fail Y Error Potentiometer defective or not connected U Signalling For detected actuator error signalling a limit relay can be switched C600 C6zZO C6d and C660 were extended by Src 24 actuator error O Positioning value limiting As already provided with the present KS 92 94 version Yp monitoring for Ymin and Ymax remains available When exceeding these limits no further pulses in the relevant direction are output The DAC function ensures that no limits are exceeded even in case of one or several actuator or potentiometer errors Due to the measurement cycle however limit exceeding by a very low value dependent of ac
153. osition of adjustment range as for main variable X1 121 User manual KS92 94 Parameters 17 8 Input processing 17 8 1 Process value handling Text 1 Description Range Default Ist Tdz Differentiation time constant for z 0 9999 s 10 HA Zero offset ratio 999 9999 0 a Factor a 3 element control 999 9999 1 E Factor b mean value control 999 9999 0 5 17 8 2 Signal pre processing Text 1 Description Range Default Signal processing for INP1 alin Measurement value correction 999 9999 0 lout Measurement value correction 999 9999 0 Adin Meaurement value correction 999 9999 100 Azolt Measurement value correction 999 9999 100 NI Scaling gradient m 0 9 999 1 E Scaling offset b 999 9999 0 aain Square root extraction gain 0 9 999 1 TF Filter filter time constant 0 999 9 s 0 5 Signal pre processing for INP3 KR Scaling gradient m 0 9 999 1 b3 Scaling offset b 999 9999 0 air Square root extraction gain 0 9 999 1 TRS Filter filter time constant 0 999 9 s 1 Signal processing for INP4 rt Scaling gradient m 0 9 999 1 Ed Scaling offset b 999 9999 0 saind Square root extraction gain 0 9 999 1 T Filter filter time constant 0 999 9 s 0 5 Signal processing for INP5 ra Scaling gradient m 0 9 999 1 bi Scaling offset b 999 9999 0 Sairia
154. p EFRA LET BER x PUA y 9 rl I gt Ba sei DN gt B Bat Bl 2087 BATH KE IT Tes SOE EdNI ps H SDEJ Z4NI KE EJH E E TE FEI de En E ma OEE EdHI FEI Wiel HEN Mill pug e Pa a HEREIN Du ls IT CANT gt g ET FI H nor eS lt O PES Gr 0587 Fan Be II R E gona SAHI FEIT p j 125587 Hark E BSKT SdNI a Fo 11940 EPS L SSE3 Sdt puz y 2 BT TE EGET I1898 gt p _ aJe p Emn a O GLET FdHl x gt Wiel hE Mil pug y Elle DU gt Zei Fl PI S4NI gt ax E Ip ax FE pry 2057 BOTH gt H TEJE A 505 SdNI gt B rege EAT TTE Bd ada 2230 ap E H 2243 SdHI gt umyj Al hd Wad x pug S pug PUA y gt 6 A FB gt axe 5h ax FEI mare Bl 25h1 BETH EI og re oman fH 55h3 9dHI Bl 0923 Mau gt Bre 3 Egh THE 4 gt p ade Fan OT B 2Lh2 9dHI z i i o Ha Well pu SES SEI 97 User manual KS92 94 12 07 2000 Configuration 163 Main groups The following main configuration groups are available for KS9x controller configuration Contr Controller function LIDD L gt page 99 Source Input allocation CAB E gt page 101 Input Input function LEON CHAT gt page 103 Outrt Output function C508 C311 gt page 107 Alarm Alarm function LAOR LAB gt page 111 Tune Self tuning LIDD gt page 112 Disr User interface cann page 112 Aus Additional function 2300 LIG gt page 113 The main configuration groups are structured in a hierarchical order whereby determination of a dialogue for prompting only t
155. point tracking is determined in configuration code L 105 WUTrac Dependent of configuration this setting can be triggered via interface front panel operation or one of control inputs di2 or dil2 gt L 9 However only the switch over type is prepared at this faciliy without selecting between internal and external set point For preparing the bumpless switch over a signal 24 V must be connected to the external contact For direct switch over a 0 signal 0 V must be applied to the contact Bumpless switch over has priority With bumpless switch over selected anywhere front panel interface or relevant control input switch over at another facility is not possible Fig 20 Set point tracking with switch over to internel setpoint Set points process value X w we WE upper set point limit W100 SWZ internal set point w process value DT effective set point internal 22 X gt 4 set point w lower set point limit WO i Time ZN ZN S Switch over Switch over We Wp gt w w gt We Wp 47 User manual KS92 94 Set point functions 6 8 2 Process value tracking The set point may be far away from the instantaneous process value e g during start up In this case the process value tracking function can be used for attenuation of the step which may occur Process value tracking causes storage of the process value as set point whereafter line out to the
156. process parameters self tuning is possible Self tuning can be started and finished via the system menu during automatic or manual mode ba ca a mo d On gt Moreover self tuning can always be cancelled by pressing the manual automatic key on the controller front Self tuning preparations e Control behaviour PID PI PD or P can be selected by the user by switching off Tn 0 or Tv 0 before self tuning start Determine which parameter set must be optimized FUFt Determine the stable correcting variable OF tra Determine the set point step Art Determine the process at rest mode C 180 QCarnd Process at rest monitoring Process at rest monitoring is at any time The process is at rest with the process value within a tolerance band of p AX 105 AX 0 5 during more than 60 seconds When the monitored variable leaves this tolerance the monitoring time counter is reset to zero With e g PiR detected during control operation and output of a widely varying stable correcting variable opt pn when starting the Na rr par time counter process at rest self tuning waiting until the full PiR time has elapsed is necessary With extended PiR monitoring monitoring is done for a regularly varying instead of a constant process variable Configuration word E 150 QCard can be used to determine the mode of process at rest detection One
157. pted is purposeful switch over y gt Y2 AM switch over is always bumpless the last correcting value is frozen and can be changed manually The M gt A switch over is different Correcting value differences are compensated as follows when switching over the integral action of the controller is set to the correcting value Ym output last plus correcting variable portions of the controller P and D action running in the background Y1 Ym Ypp Now only the integrator which slowly adapts the correcting variable to the stationary value according to the actual control deviation is active Until the D action has decayed completely the adaption can be delayed or accelerated Fig 38 Bumpless switch over corr value y A uppe corr value limiting y automatic Ypid corr value variable PO AUTOMATIC MANUAL AUTOMATIC lower corr value limiting y Yi Ym Ypd e gt time A gt M M gt A Motor actuator output action For safety reasons motor actuators may operate inversely i e they may be self opening in case of positioning signal failure e g combustion air with furnaces Although the process is clearly a heating process i e the controller action should be inverse direct action would have to be adjusted Inverting motor actuators can be taken into account by reversing the action of positioning output OUT With switching outputs relay or logic direct is the normally ope
158. r set Transmission of a parameter set to KS94 C Read out of a parameter set from a KS94 IT Long term storage of various parameter sets on hard disk or floppy LU Display of operating data Connection of PC and KS94 controller is via an RS232 TTL adaptor cable which must be ordered separately ordering information see page 43 section 12 In conjunction with the SIM KS 94 controller simulation a graphic trend display of the real process data is available User manual KS92 94 98 12 07 2000 16 4 CONTR 12 07 2000 Controller Configuration This main group determines the controller structure and function which is used as starting point for controller configuration for a particular application The main controller configuration E 17 leads to an input and output pre adjustment 80 90 1 500 259 1 This proposal must always be checked before commissioning and corrected if necessary After determination of this word no further settings are required for a large number of applications Additional function adaptions are possible via configuration words 115 and the following configurations Main controller configuration 1 COH1 Main contr CF uric Control behaviour Dp 00 signaller 1 output 01 signaller 2 outputs 02 2 pnt controller 03 3 pnt controller heating switching and cooling switching 04 3 pnt controller heating continuous and cooling switching
159. ramp with the gradients Wp Wpo Tp With step change mode the set point of the first segment is activated immediately Dependent of configuration 24 FErid either e the programmer uses the set point of the last segment until further changing Fig 69 or continues automatically with the following program if a following program was entered in FHext or e goes to rest position Wp0 Fig 70 or starting position of the following program if a following program was entered in FHext at program end The program can be started either by Run activation or de activation of the control input or via front panel operation or Preset Reset generally leads to the start Wp0 of the selected program parameter PNo Programmer RUN START STOP can be input without option via dil 2 190 or via di4 HW option B configurable E 48 PStart e Start signal via dil or di2 dil is a combination of control commands internal external reset and run and is used when di4 is not available dil 0 switches the controller to internal set point W the programmer is reset reset Wp0 With dil 0 gt 1 the programmer is running when the operation interface is set to run start the controller uses program set point Wp O This function is possible only with int ext switch over via dil 2 It is not possible with int ext switch over via the controller front panel e Run stop via di4 and timer i 42 The pr
160. remote operation no program activ front panel operation disabled Wde External set point Band Bandwidth monitoring has Lac KS94 is in local mode front stopped programmer or panel operation possible set point ramp We Program set point Gru Set point gradient presently Hea Segment number limits the rate of change Y Program number Wz Second set point Run Programmer running End Program end is reached Eset Programmer is in reset state Stor Programmer was stopped 12 07 2000 13 10 Programmer operation Programmer Programmer operation run stop reset preset is in menul via digital inputs or via interface monitoring program Fig 74 Programmer operation via front keys Bedienebene i Menue 1 lt gt i CEus Pset End i Clock i FREun FStor Prez Ostar DStor End tHet m D A preset time parameter setting Pride 1 can be entered in hours minutes times lt 99 59 or only in hours times gt 99 59 13 11 Inputs and outputs parameters configuration timer pulse LI Li Le from serial interface front Damm en rn po oO oO a 2 2 2 2 E E S E a S gt 2 2 e 3 8 8 g 3 3 2 3 S 5 O E ce a a on a a o a a configuration analog output Inputs Run stop Reset Program no 1 3
161. riablez 19 INP6 set point switch over or start up decimal point 07 Wext 20 program time net 4 measurement value alarm 08 Aw 21 program time gross 5 measurement value alarm with 09 Weff 22 program rest time suppression with set point change 10 Yp 23 Status PROFIBUS DP or start up 11 Ypid 24 faulty actor 6 Bus error PROFIBUS DP Limit comparator refered to set point all other versions are fitted with limit contact 16 8 2 Alarm 2 limit 2 The function for alarm 2 is configured Main configuration see 16 8 3 Alarm 3 limit 3 The function for alarm 3 is configured Main configuration see EN Selection is possible with OUT1 configured as alarm output En ca 16 84 Alarm 4 limit 4 The function for alarm 4 is configured Main configuration see Selection is possible only with OUT2 configured as alarm output En ca 12 07 2000 111 User manual KS92 94 Configuration 16 9 TUNE self tuning The type of controller self tuning and the type of controlled self tuning can be adjusted 0 Standard Main configuration Controller self tuning OCornd Process at rest mode o grad 0 1 grad lt 0 with inverse controller or grad gt 0 with direct controller 2 grad 0 Sau E L He oje OCnter Controlled self tuning mode no function selectable control disturbance behaviour switch over via operation switch over via control input
162. rogram end 12 07 2000 109 User manual KS92 94 Configuration 16 7 6 DO5 6 digital control outputs Additional digital control outputs are configured Main configuration digital control signal DOS Selection is possible with option C fitted See Mode Digital control signal DOS Actuator output action 00 output switched off 0 not selectable 01 controller output Y1 1 direct normally open 34 status automatic 0 manual 1 2 inverse normally closed Main configuration Digital control signal DO6 wisi Selection is possible with option C fitted d 106 Main confia Spe Mode Digital control signal DO6 Motor actuator output action 00 output switched off 0 not selectable 02 controller output Y2 1 direct normally open 35 status external 0 internal 1 2 inverse normally closed User manual KS92 94 110 12 07 2000 Configuration 16 8 ALARM 16 8 1 Alarm I limit 1 The function for alarm 1 is configured Frc Dre Alarm signal source Alarm function e Am 00 no source 12 OVC 0 no alarm don t care 0 no decimal point 01 Xeff 13 WMIN MAX Wsel 1 sensor fail 1 1 digit behind the 02 Xw 14 INP1 2 sensor fail or measurement decimal point 03 x1 16 INP3 value alarm 2 2 digits behind the 04 x2 17 INP4 3 sensor fail or measurement value decimal point 05 x3 18 INPS alarm with suppression with 3 3 digits behind the 06 auxiliary va
163. rol outputs DO Control outputs 1 4 e Set points DF 1 DPZA The set points of control outputs are adjusted in one adjustment procedure using the 4 decimals of display 2 0 off 1 on e g control output gt 1 2 3 4 0 1 0 1 off on off on e Segment times Tdi Td28 min 13 1 3 Parameter pre setting default When configuring programmer for the first time HR all segments are at first inactive switched off when leaving the configuration level The programmer outputs the reset value Wp0 factory setting 0 and reacts only on control commands run preset after the parameters of at least one segment were set A programmer the parameters of which were already set can be switched off by configuring it accordingly With re activation the previously adjusted parameters are effective again With start run the programmer starts from the instantaneous process value with the gradient of the first segment Elapsed time and rest time are matched accordingly cf search mode page 86 Fig 63 Search mode at first segment after program start Segment 1 actuall aa process value D User manual KS92 94 80 12 07 2000 13 1 4 13 1 5 13 1 6 12 07 2000 Programmer Time display Segment times are adjusted and displayed in full minutes without digits behind the decimal point Gross net and rest ti
164. s process phases In this case the max overall length of a program thus defined is 60 segments Thus automatic repetition of one or several programs is also possible Control commands operation and display relate exclusively to the instantaneously running active program segment The gross running time t Br ut is the overall time including pauses from the start of the first program segment Fig 66 Following programs heating up tempern cooling off Program 1 Program 2 Program 3 Sh i 2 3 16 17 18 19 Start O lt Program repetition Repetition of a program sequence in the order I II IH start at any point Repetition of a program sequence in the order II I II start at any point Start Execution of programs I and II with subsequent repetition of gt programs II and III start in program I gt LU User manual KS92 94 82 12 07 2000 13 1 7 13 1 8 12 07 2000 Programmer Parameter of the segments Wp0 Wei Wp2 Wp3 Wp4 Wp5 Change mode ramp step Whether the set point analog output change shall be a step or a ramp is determined by a common parameter Wricicle valid for all segments of a recipe at parameter level default ramp wpa gt e Step The set point changes to value Wpi immediately at the ps LT SE beginning of segment Segi and remains unch
165. s 2 PT100 in 2 wire connection d Potentiometric transducer e Current f Voltage Input INP3 amp Dependent of configuration this input is used for variable x2 or variable z The reference potential GND of this input is at terminal C10 see page 34 Input INP4 amp Dependent of configuration this input is used for variable x3 external set point or override control OVC The reference potential GND of this input is at terminal C10 see page 34 Input INP5 A A This input is used for variable x2 for the external set point or for external set point 4 4 Volt offset configuration level E 8 i mA i we With voltage signals A6 must be connected with the reference potential at A9 see gt m 7 zu page 34 8 8 9 9 Input INP6 This input is used for position feedback with 3 point stepping controllers for the external set point or for the external set point offset configuration level HR see page 35 User manual KS92 94 14 12 07 2000 Electrical connections 3 3 Outputs OUT Output OUT1 Q Dependent of version OUT is a continuous a logic or a relay output It may be allocated to Y1 or to alarm With logic and continuous output a protective earth must be connected to P13 The logic signal switches between 0 and 20 mA load lt 600 Q or 0 gt 12 V load gt 600 Q see page 34 Outputs OUT2 OUT4 and OUT5 These outputs are relay outputs Output OUT is configured either for y2 or for alarm see p
166. set point tracking OFF 0 ON 1 and can be used for switching over to the second set point W2 E 130 OFF 0 ON 1 Outputs The input names and numbers were selected for utmost language independent international clarity of the inputs and outputs on the process value display 7 segments during configuration Digital inputs and output are marked with lower case letters to permit clear distinction of 0 and o on the display OUT outputs Dependent of hardware there may be four switching outputs or three switching and one analog output Additionally there may be optional output OUT3 which is located on plug in options p c b C OUT can be ordered as switching or continuous output Outputs OUT2 OUT4 and OUTS are always switching and output OUTS is always analog Behaviour of outputs with initialisation All outputs are switched off for 100 ms at the end of initialisation Analog outputs take over the lower output value 0 4 mA Signal output 1 OUTI gt S00 Signal output OUTI is used for controller correcting variable Y1 Y2 As it is a universal output extensive functions can be configured Which signal shall be taken to this output must be determined at configuration word 484 Src e 00 none output switched off 05 control deviation xw 20 Wint 25 Alarm 1 Limit 1 e 01 controller output Y1 Youtl 10 process value xeff 21 Wext 26 Alarm 2 Limit 2 e 02 controller output Y2 Yout2 11 proc
167. sponse the hints given in Fig 3 must be followed we We Wert Wise iba Fig 51 i Static operating Hert principle of the 100 two point controller No ug 0 PD behaviour Tn 00 The working point is in the centre of proportional band Kor at 50 duty cycle For keeping the process constant a certain amount of energy dependent of the set point is necessary This results in a permanent control deviation which will increase with higher values for Xp1 DPID behaviour By means of the integral action the process is lined out without permanent offset The static characteristic of a two point controller is identical with the one of the continuous controller The difference is that a duty cycle is output instead of a linearly variable current signal relay contact 0 20mA logic signal or 0 24V control output Working point Yo and cycle time T at 50 duty cycle are adjustable The shortest step is 100ms Configuration Effective controller parameters E 00 CFurg 02 two point controller MZ Additional correcting variable 105 105 Ymir min correcting variable limiting 105 105 Mi max correcting variable limiting 105 105 WD working point of correcting variable 105 105 FEl proportional band 1 0 1 999 9 Tril integral action time 0 9999 s Tal derivative action time 0 9999 s Ti switching period 0 4 999 9 s 6
168. ss value determination The mean value is calculated according to equation x 1 b x1 bx2 Parameter b can be used for determining a weight ratio for the two signals If b 0 5 is entered the arithmetic mean value is calculated Fig 31 Mean value formation furnace extended operating level a INP1 Input 1 INPS Input 5 upper heat lower heat UO A 150 Process value display mm DUU weff User manual KS92 94 52 12 07 2000 Correcting variable processing 8 Correcting variable processing 8 1 8 2 12 07 2000 The following considerations in connection with correcting variable processing are valid for continuous controllers two point three point and three point stepping controllers The following diagram shows the functions and interactions of correcting variable processing Fig 32 Yp signal display of corr value Ymax Ymin actuator y limiting Second correcting value Similar to set point processing switch over to a second preset correcting value Y2 is possible The signal source for y Y2 switch over must be selected with 13 f Whether Y2 has safety functions or whether it is only a pre defined start position in defined process conditions is determined only by the use and integration into an automation concept Y2 Y switch over is bumpless Correcting variable limits Parameters Ymin a
169. ssary Signal pre processing Funcl Func2 permits adjustment of the required set point or correction characteristic as function of the input signal dependent of configuration gt INP5 3 10 INP4 428 or INP6 4 12 Offset activated has priority With selection offset active at anywhere front panel interface or the relevant control input switching over at another facility is not possible Bumplessness Set point change Set point change in both direction is always bumpless The effective set point Weff approaches the modified set point target linearly whereby gradients Grw and Grw adjustable at parameter level determine the slope The gradient function is also active with programmer however it is not effective as long as the program profile causes slower set point changes than the adjusted gradients Hereby the gradient setting can be used as safety function with incorrectly adjusted programmer For second set point W2 an independent gradient Grw2 which is valid for the two switch over directions was introduced The gradient function is switched off with Grw and Grw or Grw2 set to Fig 18 Ramp function with set point change Set points process value WwW we w2 AIRE Tim we upper set point limit W100 Set point 2 lower set point limit WO ZS FAS gt Time Change Change Set point 1 Set point 2 Set point 2 Set point 1 User manual KS92 94 46 12 07 2000 6 7 2
170. t for all outputs default preset to time Preset value system menu Timer parameter Time real time clock system menu User manual KS92 94 90 12 07 2000 Timer Timer 14 1 14 2 12 07 2000 Definition KS9x versions with built in real time clock HW option B with RS422 485 can start automatically at a pre set time For this purpose a time can be set year month day hour minute e g on 23 07 95 at 6 35 h The timer comprises a switch on time start TS and a switch off time stop a lena TE xxx Both switching times are adjusted absolutely day month year hour aim a End minute The switch off time Tstop is generally adjustable however it is not Input TE HM evaluated with the programmer The two trigger points can be used also for switching ponte TE ue over w W2 y Y2 and for controller output switch off SOURCE E 90 ff Timers Limit TS HM are adjusted at parameter level When entering a start time with an actual start time mas O Ey lt TStart Timer is displayed in Text WEN 2 us Timer function after mains recovery The behaviour is dependent of whether the start time or start and stop time are already exceeded at the time of mains recovery eo TStart lt actual time gt TStop The timer output is activated immediately and the relevant action is triggered program START
171. t change 0 100 1 1 digit behind decimal point 1 scaling reference values C 510 2 2 digits behind decimal point and C 511 are effective 3 3 digits behind decimal point X0 o physical value at 0 O Numeric value 999 9999 x100 g physical value at 0 Numeric value 999 9999 12 07 2000 107 User manual KS92 94 Configuration 16 7 2 Signal output 2 OUT2 Used for configuring the source of output OUT2 This signal output is a universal output and can be configured for extensive functions Main configuration OUT2 main co Src Tafe Mode Signal source Output stage Motor actuator output action 00 output switched off 0 relay switching 0 not selectable 01 controller output Y1 Youtl 1 direct normally open 02 controller output Y2 Yout2 2 inverse normally closed 25 alarm limitl 26 alarm2 limit2 27 alarm3 limit3 28 alarm4 limit4 16 7 3 Signal output 3 OUT3 Used for configuring the source of output OUT3 This signal output is a universal output and can be configured for extensive functions Main configuration Selection is only possible with option C fitted OUTS main Src Tyre Mode Signal source Output stage Motors SKUB TORO LEDE 00 none output switched off 12 process value x2 0 switched off 0 not selectable 01 controller output Y1 Youtl 13 process value x3 1 0 20 mA 1 direct normally open 02 con
172. troller output Y2 Yout2 20 set point Wint continuous 2 inverse normally 03 controller output Ypid 21 ext set point Wext output closed 04 position feedback Yp 22 ext Offset dWe 2 4 20 mA 05 control deviation xw 23 set point Weff continuous 10 process value xeff 24 programmer Wprg output 11 process value x1 3 0 20 mA logic Additional configuration o The optional configuration can be used for determining the functions for signal post processing This configuration word is displayed only with the option enabled OUTS add co Furic DF Function selection for signal output processin decimal point for xsi x0 x100 0 no function signal is output directly 0 100 0 no decimal point 1 scaling reference values 5 1H and 5 1 are effective 1 1 digit behind the decimal point 2 linearization segment points xs1 ysl 2 2 digits behind the decimal point 3 3 digits behind decimal point x0 o physical value at 0 g numeric value 999 9999 User manual KS92 94 108 12 07 2000 Configuration x100 g physical value at 100 O numeric value 999 9999 The configuration parameters for linearization are stored 5 as follows ae Oo 513 value pair 1 Ss xsl 5 inrut 1 outrut amp value pair 2 Er ru LM value pair 3 value pair 4 Note that the input values x values must be entered in ascending order xsl lt xs2 lt xs3 value pair 5 D t 1
173. tuator speed and inertia cannot be prevented User manual KS92 94 60 12 07 2000 12 07 2000 Special Functions Q Reset after actuator error With actuator error detection the controller switches to manual mode and displays the error When the plant trouble was removed the operator must inform the controller accordingly For this press key A or Y and or switch the controller to automatic mode If the actuator error continues the controller detects it and switches off again In any case the controller must be switched back to automatic mode by the operator d Operating limits 3 point stepping controller with position feedback or continuous controller with position control e The Yp change must be higher than 2 Q sec or 0 1 mA sec Example motor actuator with travel time Tm 60sec resistance change R 120 Q e Conductive plastics potentiometers must be used because their reliability and linearity is much better than with wire potentiometers e Any change of the motor actuator movement must cause a potentiometer resistance change e Drives with a high backlash are detected as defective Continuous controllers with position feedback e The position fed back may have a maximum deviation of 10 after filtering with T 20sec U Automatic Yp calibration To facilitate operation the automatic Yp calibration was introduced The controller changes its output to determine the two end positions and a
174. tween INP3 and INPS 80 5 2 as second ratio input is possible This input is also configured for 4 20 mA and m h gas 300 E400 x2 x0 and x100 values 0 and 100 E 3 0 04 ff and 3 t2 E H td are allocated to the input variables mia a Set point Weff effective as a relative ratio is multiplied by the stoichiometric factor s e g s 10 E I I so that a stoichiometric flow ratio can be used for calculation of the control deviation The instantaneous controlled process value is determined from the physical ratio multiplied by 1 s and displayed as a relative value burner Fig 26 Ratio control standard extended operating level Process value display ep weff A mr LU DU 4 Inn LU U HEHEBE____ 50 x1 N0 s x2 x lt s Display of material flow rates INP 5 3 x2 Y atomizing air x1 a gt gt 1000 Nm h air X W Material batching and mixing The following examples are intended to show that various control possibilities can be used This is necessary since the materials to be mixed e g paste are not always directly measurable due to their consistency Other cases may require a component to be controlled relatively to a total and not as a ratio to another component w xl x2 The first case is obvious Almost everybody knows what happens during brewing Yeast x2 must be batched in a ratio to the original wort x1 Th
175. ud rate detection 12 07 2000 113 User manual KS92 94 Configuration 16 11 5 16 11 6 16 11 7 More Fdi Forcing dig input 6 Fdir Forcing dig input 7 Fdis Forcing dig input 8 0 Controller value 1 Forcing 0 Controller value 1 Forcing 0 Controller value 1 Forcing Fila Forcing dig input 10 manat Forcing dig input 11 Fdilz Forcing dig input 12 Forcing dig input 9 0 Controller value 1 Forcing 0 Controller value 1 Forcing 0 Controller value 1 Forcing 0 Controller value 1 Forcing Forcing signal output FOUT 1 FOUT 3 FOUTS Forcing signl outp 1 Forcing signl outp 1 Forcing signl outp 1 Forcing signl outp 1 FOUTS Forcing signl outp 1 0 Controller value 1 Forcing 2 Release signal 0 Controller value 1 Forcing 2 Release signal 0 Controller value 1 Forcing 2 Release signal 0 Controller value 1 Forcing 2 Release signal 0 Controller value 1 Forcing 2 Release signal Forcing digital output Fdos6 i ig outp 5 6 0 Controller value 1 Forcing 2 Release signal 0 Controller value 1 Forcing 2 Release signal 0 Controller value 1 Forcing 2 Release signal 0 Controller value 1 Forcing 2 Release signal 0 Controller value 1 Forcing 2 Release signal H
176. uisites which are already defined for controllers are applicable e general limitation of the rate of set point change to the values adjusted for parameters Grw and Grw The gradients are adjustable with 3 digits behind the decimal point e storage of the external set point We or of program set point Wp or of process value X tracking E 06 Trac as internal set point W Tracking can be activated only when switching back to the internal set point The relevant conditions are configurable d 98 STrac a Tracking not effective or b tracking generally effective with We gt W or Wp gt W or c as b however contact di2 or dil2 is closed additionally User manual KS92 94 84 12 07 2000 Programmer 13 2 Changes in the program sequence Whilst the program is running set points and times on line can be changed Moreover segments which were not available so far can be appended The actual segment number remains unchanged Unless the actual segment is changed the relative elapsed time in the segment remains unchanged _ Past changes A change of values and times in the past already executed segments is activated only after re start after previous reset IT Future changes Future changes segments which are not reached so far are activated immediately With changes of segment time the rest time is re calculated automatically TI Present changes Changes of the actual segment time which imply a step back into the p
177. ured in the overall physical measuring range according to data sheet and linearized according to the relevant allocation table Linearization is realized by error curve approximation with up to 28 segment points User manual KS92 94 26 12 07 2000 KS92 94 function survey 5 4 4 Additional measurements 5 4 5 5 4 6 5 4 7 5 4 8 12 07 2000 Dependent of configured sensor type additional and corrective measurements are required The amplifier zero is checked with all measurement types and taken into account during measurement value calculation The lead resistances with Pt100 and potentiometric transducer and the cold junction reference temperature internal TC with thermocouples are measured additionally Filter In addition to filtering in the analog section of each input signal a 1st order filter is adjustable filter time constant 0 5 9999s configuration Scanning intervals The internal scanning interval of controllers KS92 and KS94 is 100ms A survey of input and output scanning intervals front LEDs operating keys and serial interfaces is given in the following table Description Scanning interval Circuit board Serial interfaces 100 ms B front LEDs 100 ms front Keys 100 ms front INP1 200 ms A TC with thermocouples 24s A Compensation measurement of the lead 24 A resistance with Pt100 and transducer a8 Zero correction using an
178. w rates in physical units e g Nm h at the extended operating and display level the two flow rates available as mA signals are scaled in physical units i e they can also be displayed directly e g in Nm h Set point Werf effective as a relative ratio is multiplied by the stoichiometric factor e g s 10 This means that stoichiometric material flow ratios can be used for calculating the control deviation The instantaneous controlled process value is calculated from the physical ratio multiplied by 1 s and displayed as a relative value see also Fig 26 example standard ratio control Selecting the individual material flow rates For display of the individual material flow rates in physical units the extended operating level must be selected At this level the individual inputs e g INP1 for x1 and INP3 for x3 can be shown on display 2 set point display The effective Xp refers to the process value range Xo x100 of input x1 49 User manual KS92 94 Process value calculation 7 2 3 7 2 4 Example for standard ratio control Fig 25 St chiometric combustion Standard ratio control at the example of a stoichiometric j w X1 X2 combustion Analog input INP1 is con figured for 4 20 mA with mp physical unit m h air DH 1 Values 0 and 1000 FT OR 4 L tt and d id are allocated to input variables 4 mA x0 and 20 mA x100 Atomizing air NO is added to this x1 input Selection be
179. witch over between internal set point W 0 and second set point W2 1 Switch over between automatic 0 and manual 1 mode Set point offset switch on normal 0 offset 1 Switch over between normal correcting value 0 and safe correcting value 1 Switches the controller ON 0 or OFF 1 Switch over between PI 0 and P 1 with 2 3 point and continuous controllers or feedback switch off with 3 point stepping controllers Bumpless switch over between normal correcting value 0 and safe correcting value 1 Bumpless switch over to the internal set point tracking only di2 OFF 0 ON 1 35 User manual KS92 94 KS92 94 function survey 5 7 5 71 5 7 2 Digital inputs di3 to dil2 di3 used for switch over between local 0 and remote 1 di4 used for switch over between program STOP 0 and START 1 E 132 SPrSt di5 used for programmer RESET normal 0 reset 1 di6 di7 used for program number selection with programmer 1 di6 0 1 x di8 0 1 0 1 di7 0 0 1 di9 0 0 1 1 Program 1 2 3 Parameter set 0 1 2 3 di7 di8 used for program number selection with programmer di10 minimum delimitation of the correcting variable with 3 pnt stepping controller dill maximum delimitation of the correcting variable with 3 pnt stepping controller and can be configured for switching on the effective set point offset E 190 Sclular dil2 switches over bumplessly to the internal

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