Operating manual - pma
Contents
1. Lit with limit value 1 P Rr R L 1n not exceeded Process value display Set point controller output Q Signals L ant and PAr R level KS40 1 0 Programmer or timer running Self tuning active Lf NES Q Entry in error list 71 C HL Set point5 Fc or PE is I effective UL Lt 5 Set point gradient effective pag S Manual automatic switch over Or tc a yO pHa L 2 usd O Off Automatic d O On Manual changing possible Blinks Manual oO E e changing not possible E I v a U L anF Lntr nhn KS 42 1 ivr L9 V la SD Q Enter key Keds calls up extended operating level error list 9 Up down keys changing the set point or the controller output value Manual mode spec function Lank L Uu e 9 PC connection for BlueControl engineering tool LED colours LED 1 2 3 yellow LED OK green other LEDs red aD In the upper display line the process value 1s always displayed At parameter configuration calibration as well as extended operating level the bottom display line changes cyclically between parameter name and parameter value Front view 10 Operating KS4x 1 Operation 3 2 Behaviour after power on After supply voltage switch on the unit starts with the operating level The unit is in the condition which was active before power off If KS4x 1 was in manual mode be2. Measured value monitoring alarm status storage A stored limit value can be reset via error list key or a digital input L Ha Err r Source of limit 1 2 3 0 Jpreesvale o o control deviation xw process value set point MEE NN control deviation xw with suppression after start up and set point chang De 6 Jjefc veset point Weff O _ _ 7 correcting variable y controller output Alarmheatcuwrrent function INP 0 O0 switched off ss l Overload short circuit monitoring DENEN 2 Breakandshortcircuitmonitoring w Monitoring of control loop interruption for heating EN switched off inactive 0 swithedofffinctive If k t 0 LOOP alarm is inactive FF 999999 Operating hours only visible with BlueControl OFF Swit OFF 999999 Output switching cycles only visible with BlueControl OFF lt m lt L kd Method of operation of output OUTI 0 direct normally open EEE r EN o0 active I Interruption alarm signal LOOP 0 motactive j o arie Heat current alarmsignal o O0 motactive j o active x OS l l l l l 0 notactive Q with current and voltage input signals scaling is required see chapter 5 3 Resetting the controller configuration to factory setting Default chapter 12 1 page 56 Configuration 24 Operating KS4x 1 Configur
3. PMA Proze und Maschinen Automation GmbH Industrial controller KS 40 1 KS41 1 and KS42 1 Operating manual English universal line 9499 040 62711 Valid from 8499 Gu BlueControl More efficiency in engineering more overview in operating The projecting environment for the BluePort controllers Description of symbols General information N General warning a Attention ESD sensitive devices PMA Proze und Maschinen Automation GmbH Printed in Germany All rights reserved No part of this document may bereproduced or published in any form or by any means without prior written permission from the copyright owner A publication of PMA Proze und Maschinen Automation P O Box 310229 D 34058 Kassel Germany 3 1 212 2 3 3 4 3 5 3 5 1 E E 3 5 4 She 3 5 6 3 6 SM 3 8 4 4 2 4 3 4 4 4 4 1 4 4 2 4 4 3 4 4 4 4 4 5 4 4 6 4 4 7 Contents NIOUNIING v i y m 2 S Z Z S Xx E808 wee we 90 S m RON X os 5 Electrical connections lt 2 S s se se s s s s s eevee 6 Connecting diagram 22 6 Terminal connection 2 2 eee ee 6 Operin xo 9o Roe 2 k 2 S XS REX eee ees 10 PrOD VIW s Z 2993 5 5 5935 99959959 9 9593555k5 10 Behaviour after power on 2 22r 11 Operating level 1 4999 839 5 3 99 9 9954953 11 Maintenance manager Error list 12 Self tuning X s ooa ae eee eRe eee EKER Ee 14 Preparation for s
4. AN O AN Programmer Run Stop see page 44 no function switch over via interface is possible DI3 only visible with OPTION Blockage of hand function Reset of all error list entries 4 O jdret S _ l inverse 2 togglekeyfunction O Forcing dil only visible with BlueControl 00 No forcing Forcing via serial interface Il Switching off the controller Il 2 DI3 only visible with OPTION DD only visible with OPTION 2 3 4 2 3 4 2 3 4 2 3 4 3 fDII Operating KS4x 1 27 Configuration Configuration level fDI2 Forcingdi2 only visible with BlueControl 0 O jNofodng 0 0 0 __ Forcingviaserial interface wwe Forcing di3 only visible with BlueControl EE 0 JNefodng gt No forcing Forcing via serial interface __ Baudrate of the interface only visible with OPTION 2 0 2400Baud eee 1 9 80Bad 2 9600Bad 3 IU Baud nddr 1 7 _ Address on the interace only visible with OPTION 1 Parity only visible with OPTION l O NEN no parity 2 stop bits l even parit odd parit te m s Delay of response signal ms only visible with OPTION Unit 0 wihouunit 00000 000000000000 WE ecu point max number of digits behind the decimal voin 0 no digit behind the decimal point 1 I digit behind the decimal point 2 2dieits behind the
5. Err LED 1s lit can be acknowledged and deleted with the digital input dil 2 3 or the Kev Configuration see page 27 Lanf L HD e K Day o n n n If an alarm is still valid that means the cause of the alarm is not removed so far Err LED blinks then other saved alarms can not be acknowledged and deleted e Self tuning heating d AH and cooling A d R C error status Description n Noerror a ae Faulty control action Re Reauligurswontalen mene dey sure controller inverse direct No response of process The control Ud Is perhaps not closed check sensor variable connections and p Low reversal point Increase nd ru max a jimiting AH or decrease d n output limiting H L a EE Danger of exceeded set point I necessary increase inverse or reduce direct set point parameter determined a i change too small Increase H d H H max output limiting 4H or reduce gt 5 0 Moree min output limiting 4 Set point reserve too small Increase set point invers cece S direct or increase set point range SPR A I 5EEP SPLG and SPH i Operating KS4x 1 Toa Maintenance manager Error list Operation 3 5 Self tuning For determination of optimum process parameters self tuning 1s possible After starting by the operator the controller makes an adaptation attempt where by the process characteristics are used to calculate the parameters for fast line out to the set point with
6. t The operator can correct the lower display value by pressing the keys Subsequently he confirms the display value by pressing key t The input value of the upper scaling point is displayed The operator must adjust the upper input value by means of the process value simulator and confirm the input value by pressing key LJ t The display value of the upper scaling point is displayed Before calibration Hut 1 equals a i The operator can correct the upper display value by pressing keys Subsequently he confirms the display value by pressing key aD The parameters uL t Gut 11 changed at LAL level can be reset by adjusting the parameters below the lowest adjustment value UF F by means of decrement key Operating KS4x 1 43 Programmer Programmer Tum roms W X 2r t 2r C L lt m bats L CER ae a L me W Programmer set up For using the controller as a programmer select parameter BF n 1 in the Lant menu page 21 The programmer is started via one of digital inputs dil 3 Which input shall be used for starting the programmer is determined by selecting parameter Bc un e 3 4 inthe anf menu accordingly page 23 For assigning the program end as a digital signal to one of the relay outputs para meter F E nd 1 must be selected for the relevant output Gut 1 0 r 3 in the Lant menu page 26 27 Programmer parameter setting A programmer with 4 segments 1s ava
7. the unit must be disconnected completely After completing this work re shut the unit and re fit all covers and components Check if specifications on the type label must be changed and correct them if ne cessary Caution When opening the units components which are sensitive to electrostatic dischar ge ESD can be exposed The following work may be done only at workstations with suitable ESD protection Modification maintenance and repair work may be done only by trained and aut horized personnel For this purpose the PMA service should be contacted The cleaning of the front of the controller should be done with a dry or a wetted spirit water kerchief Operating KS4x 1 55 Safety hints 12 1 Resetting to factory setting 9 e Resetting to factory setting In case of faultyconfiguration KS4x 1 can be reset to the default condition gt i uus NC PX mr L s SS gt eZ p f inm LI SPx JA A L UL a For this the operator must keep the keys increment and decrement pressed during power on Then press key increment to select YE Confirm Ia resetting with Enter and the copy procedure is started display L amp P 7 C Afterwards the devia restarts In all other cases no reset will occur timeout abortion If one of the operating levels was blocked and the safety lock 1s open reset to factory setting 1s not possible If a pass nu
8. 00 12 Operating KS4x 1 F Front view sns 10 I Input INP Configuration 23 Parameters 39 Technical data 51 Input INP2 Configuration 23 Parameters 39 Technical data 51 Input scaling 40 K Kalibrierung LAL 2 0 41 L LED Ada LED 10 ire LED 394429593 10 J LED raserer ery pa 10 LED colours 10 Sve LED o ee eae 2 2 gt 10 run LED 4 10 SPX LED ys 4 ede de ee 10 M Maintenance manager 12 13 Manual tuning 17 Mounting 5 O Offset correction 4 Output OUTI Configuration 24 Technical data 2 2 52 Output OUT2 Configuration 25 Technical data 52 Output OUT3 Configuration 25 Technical data 52 P Parameter setting level Parameter survey ES Parameters 38 39 97 Power supply 52 Programmer Changing segment end setpoint 45 Changing segmenttime 45 Parameter setting 44 set up oaa lr 44 Starting Stopping 44 R Resetting to factory setting 56 Resistance thermometer measuring range S Safety hints x oa 95 55 56 safety switch 3 Safety toSt a v tee pa ee k 3 53 Self tuning Cancelation 15 Cancelation causes 16 Old uo esa m Q lt m m X w s 15 S
9. 49 4 3 Set point processing The set point processing structure 1s shown in the following picture Xeff Z a internal setpoint external setpoint INP2 0 4 20 mA coc 2 setpoint ar c Index programmer G QE CO eo0000 e co A L U limitation actual setpoint The ramp starts at process value with the following switchings int ext setpoint switching configuration 5 HE n CD 3 A E switching Operating KS4x 1 int ext setpoint switching 5P 5P switching Manual Automatic switching at power on 29 Set point processing Configuration level 4 4 Configuration examples 4 4 1 On Off controller Signaller inverse Tf set point controller signaller with one output inverse action e g heating applications action Link i direct control output Y 1 active 0999 switching difference symmetrical to the trigger point 999 9999 set point limit low for Weff 1999 9999 set point limit high for Weff D C mm em Rm em OC p P E ps me C al r L r L lt C lt r3 P amp OC E m en L lt E HP eam 1 sss 7 Dm gt L Pe ae C E P px m K L D L Cm Gu C dum lad Gu dJ NS w gt gt L Gu a mi P lt sma O lt Des L L lt m zi n L FP md C P 0 L CENE Sm
10. 9999 min cycle time 2 cooling SH 0 9999 neutr zone in units of phys quantity C RC L R asas se Wwe Configuration examples 32 Operating KS4x 1 Configuration level 4 4 4 3 point stepping controller relay amp relay 10096 10096 dut XC Tf L Tag SRS te E D gt qx set point controller 3 point stepping controller inverse action e g heating applications action Luk 1 direct control output Y1 active control output Y2 not active action U u E C direct control output Y1 not active control output Y2 active 1 9999 proportional band 1 heating in units of phys quantity e g C 1 9999 integral time heating in sec 9999 derivative time 1 heating in sec 0 4 9999 min cycle time heating 0 9999 neutral zone in units of phy quantity 0 1 9999 min pulse length in sec 3 9999 actuator travel time in sec 1999 9999 set point limit low for Weff 1999 9999 set point limit high for Weff For direct action of the 3 point stepping controller the controller output action must be changed Lanf intr L AcE I C L anr zh ca sx L UT Li LCH lt puc p P q C al r L P L ae P C ra ar NC r lt lt E me anf U L i L UT LLL I K haf lt 1 m VU Ime ew P C a me Pe a nE LJ L 01 U U C C Ss Des L SER
11. C to DIN 4752 Table 1 Thermocouple measuring ranges L E Fe CuNi DIN 100 900 C 148 1652 F T EeCuNi 100 1200 C 148 2192 F K Nini a L148 2462F Ek IK N JNicosi Nisl 100 13009C 148 2329F S2K 02K R jPtRh Pti36 0 1760C 32 3200mF S 2K 02K Table 2 Resistance transducer measuring ranges Poo Table 3 Current and voltage measuring ranges Range Input resistance Accurac Resolution 0 10 Volt 110kQ 0 20 mA 49 Q voltage requirement lt 2 5 V Operating KS4x 1 63 Safety hints Safety hints This unit was built and tested in compliance with VDE 0411 1 EN 61010 1 and was delivered in safe condition The unit complies with European guideline 89 336 EWG EMC and is provided with CE marking The unit was tested before delivery and has passed the tests required by the test schedule To maintain this condition and to ensure safe operation the user must follow the hints and warnings given in this operating manual The unit is intended exclusively for use as a measurement and control instrument in technical installations N Warning If the unit is damaged to an extent that safe operation seems impossible the unit must not be taken into operation ELECTRICAL CONNECTIONS The electrical wiring must conform to local standards e g VDE 0100 The input measurement and control leads must be kept separate from signal and power supply leads In the in
12. Gu ON 4 LI LC LA e CO wma Se m Seay d Rn P REP gt inm C ae Sap ee ome EP Qum lt a m De L s m aw G TY X A nd O gt ro L L Lm PO P Lm P P Pr SS ear M nad a lt wett M 100 00 setpoint 3 50 000 lt lt process value 0 000 00 25 00 00 26 00 00 27 00 00 28 00 output 1 gt Y output 2 gt TZ Operating KS4x 1 do Configuration examples Configuration level 4 4 5 Continuous controller inverse Lank Lnkr Fra 0 set point controller Leng continuous controller PID Luck U inverse action e g heating applications Lanf utd DK HP i d U utE 32 type 0 4 20mA 1999 9999 scaling analog output 0 4mA 1999 9999 scaling analog output 20mA 0 1 9999 proportional band 1 heating in units of phys quantity e g C 1 9999 integral time 1 heating in sec 9999 derivative time 1 heating in sec 0 4 9999 min cycle time 1 heating 1999 9999 set point limit low for Weff 1999 9999 set point limit high for Weff wea em Pe ra C3 ca C re py a a DuC gt qu d M HP em d r rns a 9 Sea DuC a EI m EBD Gun E Dem lt LA a m gt Dey a Wwe io E ro E C3 A A ad C dum Lm Ln Pr Pr Pr T lt C3 Dey ee For direct action of the continuous controll
13. mA configurable Signal range 0 approx 22mA Max load 500 Q Load effect no effect Resolution lt 22 uA 0 1 Accuracy lt 40 uA 0 296 Voltage output 0 2 10V configurable Signal range 0 11 V Min load gt 2kQ Load effect no effect Resolution lt 11 mV 0 1 Accuracy lt 20 mV 0 2 OUT3 used as transmitter supply UNIVERSAL SUPPLY 24 V UC AC voltage 20 4 26 4 V AC Frequency 48 62 Hz DC voltage 18 31 V DC class 2 Power consumption approx 7 0 VA BEHAVIOUR WITH POWER FAILURE Configuration parameters and adjusted set points control mode Non volatile storage in EEPROM BLUEPORT FRONT INTERFACE Connection of PC via PC adapter see Accessory equipment The BlueControl software is used to configure set parameters and operate the KS4x 1 BUS INTERFACE OPTION Galvanically isolated Physical RS 422 485 Protocol Modbus RTU Transmission speed 2400 4800 9600 19 200 bits sec Address range 1 247 Number of controllers per bus 32 Repeaters must be used to connect a higher number of controllers ENVIRONMENTAL CONDITIONS Output power 22 mA z 13V OUTS used as logic output Load 500 W 0 lt 20 mA Load 500 W 0 13 V POWER SUPPLY Dependent of order AC SUPPLY Voltage 90 260 V AC Frequency 48 62 Hz Power consumption approx 7 0 VA Protection modes Front panel IP 65 NEMA 4X Housing IP 20 Terminals IP 00 Permissi
14. only yes yes basic diagnostic functions no no yes saving data file and engineering no yes yes printer function no yes yes online documentation help yes yes yes implementation of measurement value correction yes yes yes data acquisition and trend display SIM only yes yes wizard function yes yes yes extended simulation no no yes programmeditor KS 90 1prog only no no yes The mini version is free of charge at your disposal as download at PMA home page www pma online de or on the PMA CD please ask for At the end of mum B File Edit View Device Extras Window Help j l x the installati OEEC ss mi on the licen 5 Configuration ce number Hen ven E has to be 5 Opens EX A Output 2 rs ye Cancel S tate d Of 8b Output 3 igo By Logic Licence type LL Ry Other Expiry date DEMO mode oo Setpoint A Programmer TIMENS Repeal n Sen Ry Limits enter Your licence number Cancel Licence number 1234 5678 3000 At DEMO eee peo mode the li Soar cence num ber can be stated subse quently un SUME Ready der H e Ip M Start Posteingang Microsoft D X Corel VENTURA 8 RAK 8i BlueControl Parame THAE 1529 Licence gt Change Operating KS4x 1 49 Versions BET versions KS4 1 00 00 KS 40 1 1 8 DIN 0 KS 41 1 1 8 DIN landscape 1 KS 42 1 1 4 DIN 2 Flat pin connectors 0 screw terminals 1 90 250V AC 3 relays 0 24V
15. switch or push button Connection of output Ur option Supply voltage connection for external ener gization Connection of bus interface option RS422 485 interface with Modbus RTU protocol Operating KS4x 1 7 Terminal connection Electrical connections di2 3 U 2 wire transmitter supply OUT3 transmitter supply Option If Ur and the universal output OUT3 is used there may be no external galvanic connection between measuring and output circuits OUT3 as logic output with solid state relay series and parallel connection Series connection Parallel connection NN As 104 lt 3 os M a302 KE Ap Terminal connection 8 Operating KS4x 1 Electrical connections RS485 interface with RS232 RS485 interface converter max 1000m Twisted Pair RT i RGND connection optional Rr 120 200 Ohm Interface description Modbus RTU in seperate manual see page 50 KS4x I connecting example L1 L2 TB 40 1 Temperature limiter heating VV N1 N2 TB 40 1 Temperature limiter Standard version 3 relays TB40 100 0000D 000 other versions on request N CAUTION Using a temperature limiter is recommendable in systems where overtemperature implies a fire hazard or other risks Operating KS4x 1 9 Terminal connection Operation Operation 3 1 Front view Status of switching outputs n j a both t 2
16. to 100 is not possible because the process must be kept within defined limits Values T and Xmax step change from 0 to 100 or At and Ax partial step re sponse can be used to determine the maximum rate of increase Vmax LA 10096 Y s h do l Tu x Tg i Tg Xmax Xm AX At Vax gt Tu t i Operating KS4x 1 correcting variable control range delay time s recovery time s maximum process value Xmax Ax af 2 max rate o Te At increase of process value T7 Manual tuning Operation The control parameters can be determined from the values calculated for delay time T maximum rate of increase Vmax control range X and characteristic K ac cording to the formulas given below Increase Xp if line out to the set point os cillates Parameter adjustment effects increased damping slower response to disturbances slower reduction of duty cycle increased damping slower reduction of duty cycle reduced damping faster line out faster reduction of duty cycle Formulas Pb phy units kd tf kets Cr a th Z 3 poiat controllers w os n oe the cycle time mustbe PE 36 FF 6 Tu adjusted to ea E d ke x025 Tu 3 pointstepping L7 K Tu 2 Tu _ 3 7 Alarm handling Max three alarms can be configured and assigned to the individual outputs Ge nerally outputs uk t Qut 3 can be used each for alarm signalling If
17. AC 18 30VDC 3 relays 1 90 250V AC 2 relays mA logic 2 24VAC 18 30VDC 2 relays mA logic 3 0 1 0 Configuration to specification 9 no manual 0 manual german D manual english E manual french F 0 U D G no option RS422 485 Transmitter power supply di2 di3 Standard configuration Standard CE certified cULus certified with screw terminals only DIN 3440 certitied German Lloyd certified Accessories delivered with the unit Operating manual if selected by the ordering code 2 fixing clamps operating note in 15 languages Accessory equipment with ordering information Description Order no Heating current transformer 50A AC 9404 407 50001 PC adaptor for the front panel interface 9407 998 00001 Standard rail adaptor 9407 998 00061 Operating manual German 9499 040 62718 Operating manual English 9499 040 62711 Operating manual French 9499 040 62732 Interface description Modbus RTU German 9499 040 63518 Interface description Modbus RTU English 9499 040 63511 BlueControl engineering tool Mini Download www pma online de BlueControl engineering tool Basic 9407 999 11001 BlueControl engineering tool Expert 9407 999 11011 50 Operating KS4x 1 Technical data INPUTS PROCESS VALUE INPUT INP1 Resolution gt 14 bits Decimal point U to 3 digits behind the decimal point adjustable 0 000 9999 s 100 ms 2 point or offset correction Dig input filter Scanning cycle Measured value correc
18. TION Configurable as switch or push button Optocoupler input for active triggering Nominal voltage 24 V DC external Current sink IEC 1131 type 1 Logic 3 5 V Logic 1 15 30 V Current requirement approx b mA TRANSMITTER SUPPLY Ur OPTION 22 mA z18 V If the universal output OU 3 is used there may be no external galvanic connection between measuring and output circuits GALVANIC ISOLATION Safety isolation Function Isolation Power supply Process value input INP1 connections Supplementary input INP2 Digital input dil Power OUTPUTS RELAY OUTPUTS OUT1 OUT2 2 NO contacts with common connection 500 VA 250 V 2A at 48 62Hz resistive load 6V 1 mA DC Contact type Max contact rating Min contact rating 51 Technical data Operating life 800 000 duty cycles with max electr rating OUT3 USED AS RELAY OUTPUT Contact type potential free changeover contact 500 VA 250 V 2A at 48 62Hz resistive load 5V 10 mA AC DC 600 000 duty cycles with max contact rating Max contact rating Min contact rating Operating life electr Note If the relays OUT1 0UTS operate external contactors these must be fitted with RC snubber circuits to manufacturer specifications to prevent excessive switch off voltage peaks OUT3 AS UNIVERSAL OUTPUT Galvanically isolated from the inputs Freely scalable Hesolution 11 bits Current output 0 4 20
19. ation level Default Solid state relay SSR short circuit signal BEEN not active l active s Timer end signal 0 notactive active See Programmer end signal 0 notactive NPHUINP2emorsgnal O motactiVe x C O not active l active Forcing OUTI only visible with BlueControl No forcing Forcing via serial interface Description Default Signal type selection OUT3 r logic only visible with current logic voltage ela BEEN NENNEN ss ws NENNEN r I IS w O TYP 0 direct normallyopen O j _ invrse normalycloed L o EE NN w a Controller output Y1 Y2 only visible when O TYP 0 active l not active active Interruption alarm signal LOOP only visible when O TYP 0 active Heat current alarm signal only visible when O TYP 0 not active active l 2 3 4 5 l l l l l 0 notactive s m not active G O Wa as ss Operating KS4x 1 25 Configuration Configuration level Default Solid state m SSR short circuit signal only visible when O TYP 0 jmotative j o Tag INP1 INP error only visible when O TYP 0 not active active pue ponen Scaling of the analog output for 0 0 4mA or 0 2V only visible when O TYP 1 LOU usd Scaling of the analog output for 100 20mA or 10V only visible when O TYP 1 acna source of the analog output OUT3 only visible when l O TYP 1 5 2 controlle
20. ble temperatures For specified accuracy 0 60 C Warm up time gt 15 minutes For operation 20 65 C For storage 40 70 C Humidity 75 yearly average no condensation Shock and vibration Vibration test Fc DIN 68 2 6 Frequency 10 150 Hz Unit in operation 1g or 0 075 mm Unit not in operation 2g or 0 15 mm Shock test Ea DIN IEC 68 2 27 shock 15g Duration 11ms 52 Operating KS4x 1 Technical data Electromagnetic compatibility Thermal transfer plants with organic transfer Complies with EN 61 326 1 media to DIN 4754 for continuous non attended operation Oilheated plants to DIN 4755 GENERAL cULus certification Type 1 indoor use Housing File E 208286 Material Makrolon 9415 flame retardant Mounting Flammability class UL 94 VO self extinguishing Panel mounting with two fixing clamps at Plug in module inserted from the front top bottom or right left High density mounting possible Safety test i N Complies with EN 61010 1 VDE 0411 1 Mounting position uncritical Overvoltage category I Weight 0 27kg Contamination class 2 Accessories delivered with the unit Working voltage range 300 V Operating manual Protection class Fixing clamps Certifications Type tested to DIN EN 14597 replaces DIN 3440 With the according sensors applicable for Heat generating plants with outflow temperatures up to 120 C to DIN 4751 Hot water plants with outflow temperatures above 110
21. blinking until the self tuning error was acknowledged in the error list 2 Press key E if configured The controller goes to manual mode The Err LED continues blinking until the self tuning error was acknowleged in the error list 3 Press key Display of error list at extended operating level After acknowledgement of the error message the controller continues control in automatic mode using the old parameters Cancellation causes page 13 Error status self tuning heating Hd R H 1 and cooling Aa AE 3 5 6 Examples for self tuning attempts Self tuning controller inverse heating or heating cooling Start heating power switched on Heating power Y is switched off 69 When the change of process value X was constant during one minute Q the power is switched on At the reversal point the self tuning attempt 1s finished and the new para meter are used for controlling to set point W Start heating power switched off The controller waits 1 5 minutes 69 Heating power Y is switched on 6 At the reversal point the self tuning attempt 1s finished and control to the set point is using the new parameters W gt lt t 10096 Y 096 Start lt reversal point Nit eS TAS FESS TU ES blinks XA W oa t 10096 Y 096 stato 2 lt reversal point ae S41 7 2 EU N S FIAS blinks 16 Ope
22. decimal point 3 digits behind the decimal point NO L dEL 0 200 Modem delay ms FrEq Switching 50 Hz 60 Hz only visible with BlueControl O 50i 60 Hz ICof Block controller off only visible with BlueControl 0 0 Released oo G Ada as Block auto tuning only visible with BlueControl Released Blocked Exo WE Block extended operating level only visible with BlueControl 0 Released Blocked Pass OFF 9999 Password only visible with BlueControl OFF Configuration 28 Operating KS4x 1 Default l l l Configuration level Block parameter level only visible with BlueControl Released Blocked Block configuration level only visible with BlueControl Released Block Block calibration level only visible with BlueControl Released Blocked lt gt BlueControl the engineering tool for the BluePort controller series 3 engineering tools with different functionality facilitating KS4x 1 configuration and parameter setting are available see chapter 10 Accessory equipment with ordering information In addition to configuration and parameter setting the engineering tools are used for data acquisition and offer long term storage and print functions The enginee ring tools are connected to KS4x 1 via the front panel interface BluePort by means of PC Windows 95 98 NT and a PC adaptor Description BlueControl see chapter 9 BlueControl page
23. e d 1999 9999 trigg point separation suppl cont A Y Off in units of phys quanti ty PHrH SEEP SPL 1999 9999 set point limit low for Weff SPH 1999 9999 set point limit high for Weff Operating KS4x 1 o9 Configuration examples Configuration level 4 4 7 KS4x 1 with measured value output mA V phys quantity 90 250VAC 24VUC 3 e LA lt qu lt a Des L 0 20mA continuous 4 20mA continuous Hut 3 0 10V continuous Hut 3 2 10V continuous mk U U UL mk U U UL Hoku 1999 9999 scaling Hut 3 for 0 4mA or 0 2V Huk i 1999 9999 scaling Hut 3 for 20mA or 10V Mare 3 signal source for Hut is the process value Configuration examples 36 Operating KS4x 1 Parameter setting level Parameter setting level 5 1 Parameter survey h Parameter setting level r Control and Set point and L E m end A a L L D D D EI PV Vt bs m L w C3 L Adjustment s The parameters can be adjusted by means of keys e Transition to the next parameter is by pressing key e After the last parameter of a group dank is displayed followed by automatic change to the next group aD Return to the beginning of a group is by pressing the key for 3 sec If for 30 sec no keypress is excecuted the controler returns to the process value and setpoint display Time Out 30 sec Parameter survey 97 Operatin
24. easured value correction i or is chosen The measured value can be matched in the calibration menu LAL Two me thods are available Offset CORTON LanF 1 nF i Larr standard setting offset correction possible on line at the process 2 point rem LantF 1 na i JL arr disolay sfandard seffing 2 point correction is possible off line with process value simulator C3 C p gt b Operating KS4x 1 41 Calibration level Offset correction L pnp in t Larr ni 1 The input value of the scaling point is displayed The operator must wait until the process 1s at rest Subsequently the operator acknowledges the input value by pressing key 3 Hut i The display value of the scaling point is displayed Before calibration Hui 1 is equal to nL t The operator can correct the display value by pressing keys Subsequently he confirms the display value by pressing key 42 Operating KS4x 1 Calibration level 2 point correction Lanf np Larr i EY Bult Foe tnt gt Tutt End nk 1 The input value of the lower scaling point is displayed The operator must adjust the lower input value by means of a process value simulator and confirm the input value by pressing key U uL t The display value of the lower scaling point is displayed Before calibration Gut t equals T ni
25. elf tuning 14 Self tuning sequence faa vox RE a 14 Self tuning start ss s lt ce eww Q w w W Gw w Q lt w Q S ene 15 Self tuning cancellation 15 Acknowledgement procedures in case of unsuccessful self tuning 16 Examples for self tuning attempts 16 Manualtuning 2 n 17 Alarm handling 18 Operating structure 2 2 ee ee s 20 Configuration level s o 21 Configuration survey 21 Configuration ooo e 22 Set point processing llle 20 Configuration examples 30 On Off controller Signaller inverse 30 2 point controller Inverse llle 31 3 point controller relay amp relay n 2 rss 32 3 point stepping controller relay amp relay 33 Continuous controller inverse ee ee 34 AZ Y Off controller 2 point controller with pre contact 35 KS4x 1 with measured value output 4 36 Operating KS4x 1 9 Parameter setting level 37 5 1 Parameter survey 0 0 0 2 eee eee 37 R 37 MAMMA ER 54 Parameters hat oe eed ee oe ee hee wea EU S 38 5 5 Inputscaling oa ee 40 5 5 1 Input aP b llle Rs 40 55 22 Input ng 2 2424 e
26. er the controller action must be changed Lan intr Leck b To prevent control outputs dut and Gut c of the continuous controller from switching simultaneously the control function of outputs 0 uE 1 and Huk must be switched off i anr Hut t and duke Yt and Mg e 9 Configuration examples 34 Operating KS4x 1 Configuration level 4 4 6 AZ Y Off controller 2 point controller with pre contact n C D C D wl U A AJ lt m D em EE aaa Y T set point controller A Y Off controller inverse action e g heating applications action Link i direct control output Y active control output Y2 not active action llu E C direct control output Y1 not active control output Y2 active 1 9999 proportional band 1 heating in units of phys quantity e g C r _ E r L Lu LL a Dew We 4 14 _ gt aap dme F 441 um nom me rm P REP Gm lt C2 Pg LCA Dui REP eu C3 J x lt _ lt m gt an me i L L anr L L Ut LLL Y Lc m Vut an me mr rane 1 L J Lu U U L L 1 a al e E P A re CC es m L lt x a gt D am dd NN gt 9 M inm ket 1 9999 integral time heating in sec Edi 1 9999 derivative time 1 heating in sec Ed 0 4 9999 min cycle time 1 heating SH 0 9999 switching differenc
27. et point processing 29 T Thermocouple measuring range 51 Timer Display run LED 48 Operating modes 46 Signal end Re s 48 Timer start x 9 94 eG 47 Tolerance band 47 V Versions guns dee 9 355 50 Voltage signal measuring range 51 58 Operating KS4x 1 Operating KS4x 1 od 2 9499 040 62711 of c oo c a e o c3 c3 Z e Q N m 5 o lt e SQ i e N as e e e SQ N lt S gt 3S un lt Anderungen vorbehalten P O B 310 229 D 34058 Kassel Germany Subject to alterations without notice PMA Proze und Maschinen Automation GmbH Sous r serve de toutes modifications Printed in Germany 9499 040 62711 07 2011
28. evel At L ant level the right decimal point of the upper display line blinks When safety switch Loc is open only the levels enabled by me PASS ans of BlueControl engineering tool are visible and accessible by entry of the password adjusted by means of BlueControl en gineering tool Individual parameters accessible without password must be co pied to the extended operating level Factory setting Safety switch Loc closed all levels accessible without restriction password FASS SUFF Safety switch Password entered with Function disabled or enabled Access via the instrument Loc uePort with BluePort front panel closed OFF password disabled enabled enabled open OFF password disabled disabled open enabled open Password enabled enabled after password entry Operating structure 20 Operating KS4x 1 Configuration level E Configuration level 4 1 Configuration survey Lan Configuration level l mr LLLI L nE r Control and self tuning Digital inputs Adjustment e The configuratiuons can be adjusted by means of keys e Transition to the next configuration is by pressing key e After the last configuration of a group d ant is displayed and followed by automatic change to the next group aD Return to the beginning of a group is by pressing the key for 3 sec Operating KS4x 1 21 Configuration survey Configuration level 4 2 Configuration Value range Description efault Basic co
29. fore power off the controller starts with cor recting value Y2 after switching on again 3 3 Operating level The content of the extended operating level is determined by means of BlueCon trol engineering tool Parameters which are used frequently or the display of which is important can be copied to the extended operating level Automatic Manual Extended operating level L W Errorliste if error exists display switching Operating KS4x 1 11 Behaviour after power on Operation 3 4 Maintenance manager Error list With one or several errors the extended operating level always starts with the error list Signalling an actual entry in the error list alarm error is done by the Err LED in the display To reach the error list press twice Err LED status Proceed as follows blinks Alarm due to existing Determine the error type in the error list via the Status C error error Error removed Acknowledge i the alarm in the error list pressing Status i Alarm not acknowledged key A or The alarm is Not visible except wma T Status U all alarm entries deleted Error list cannot be removed Return unit to our factor Internal error canbe e g EMC trouble Keep measurement and power supply cables in separate runs Ensure that ee suppression of Hardware error Codenumber and hardware Contact PMA service are not identical Elektronic Optionca
30. g KS4x 1 Parameter setting level 5 2 Parameters L nE r Proportional band 1 2 heating in BRZ 1 999 Proport in ph E id 1 999 Integral action time 1 heating f 180 1 9999 9999 1 9999 0 4 9999 Minimal cycle duration 1 2 heating cooling s The minimum impulse is 1 4 x t1 t2 0 9999 Dead zone or switching differential for on off control phys dimensions 1999 9999 Trigger point speration for series contact A Y Off phys dimensions 0 1 9999 3 9999 Actuator response time for servo motor s 120 120 120 12 120 12 120 12 120 120 Limitation of the mean value Ym Max deviation xw at the start of mean value calculation phys dimensions QD Valid for Lan a hr dF At dP t 2 94 also 0 1 0 01 0 001 1E Default FL 1999 9999 Set point limit low for Weft 0 5H a 1999 9999 Set point limit high for Weff 90 a c 1999 9999 Set point 2 0 r 5P 0 999 Set point gradient min DEE NENNEN 0 3P 1999 9999 Set point only visible with BlueControl O c ral REUT 1999 9999 Segment end set point 1 PEU 0 999 Segmettim l mn 60 artic 1999 9999 Segmentendset point2 m9 Ptr 0 999 Segment time 2 min 5 P3 1999 999 Seoment end set point 3 200 PEL 0 9999 Segment time 3 min Operating KS4x 1 38 Parameters Parameter setting level Default SPA 1999 9999 Seomen
31. ilable to the user Determine a segment du ration FE C PEAY in minutes and a segment target set point 5 P H t 5 Fd 4 for each segment in the P Hr A menu gt page 38 Starting stopping the programmer Starting the programmer is done by a digital signal at input dil 3 selected by pa rameter Pr un page 23 The programmer calculates a gradient from segment end setpoint and segment time This gradient 1s always valid Normaly the programmer starts the first seg ment at process value Because of this the effective run time of the first segment may differ from the at P Ar R level setted segment time process value z set point After program end the controller continues controlling with the target set point set last If the program is stopped during execution signal at digital input dil 3 is taken away the programmer returns to program start and waits for a new start signal 44 Operating KS4x 1 Programmer lt Program parameter changing while the program is running is possible Changing the segment time Changing the segment time leads to re calculation of the required gradient When the segment time has already elapsed starting with the new segment is done di rectly where the set point changes with a step Changing the segment end setpoint Changing the set point leads to re calculation of the required gradient In order to reach the new set point during the segment rest time whereby the required gra die
32. ion level Default jSemortypselction ss 0 thermocouple type L 100 900 C Fe CuNi DIN 1l thermocouple type J 100 1200 C Fe CuNi 2 thermocouple t pe K 100 1350 C NiCr Ni 3 thermocouple type N 100 1300 C Nicrosil Nisil U 0 4 thermocouple type S 0 1760 C PtRh Pt10 Z 5 thermocouple type R 0 1760 C PtRh Pt13 gt 20 Pt100 200 0 100 0 C 21 Pt100 200 0 850 0 C 22 Pt000 2000 200 09O C o o Z o o y oO LES special 0 4500 Ohm pre defined as KTY11 6 30 0 20mA 4 20mA y y y O 4 0 10V 2 10VQ EN es only at RL YP 23 KTY 11 6 30 0 20mA and 40 0 10V adjustable mE Oo 0 1 BENE NE a Linearization to specification Creation of linearization table withBlueControl EE tool possible The characteristic for 11 6 temperature sensors 1s preset Measured value correction scaling Without scaling Offset correction at LAL level 2 point correction at LAL level Scaling at PAr H level Forcing INP1 only visible with BlueControl No forcing l 2 3 4 3 20 2l 22 23 30 40 l l 2 3 0 20mA 4 20mA 0 50mA AC Forcing INP2 only visible with BlueControl No forcing Forcing via serial interface Configuration 29 Operating KS4x 1 Configuration level JFumtionoflimit 2 O 0 0 10 O switched off 1 jmeauredvaluemonitring
33. ller attempts to calculate the optimum control parameters from the process response If this is done successfully the optimized parameters are taken over and used for line out to the set point With a 3 point controller this is followed by cooling After completing the Ist step as described a correcting variable of 100 100 cooling energy is output from the set point After successfull determination of the cooling parameters line out to the set point is using the optimized parameters Self tuning 14 Operating KS4x 1 Operation Start condition Rest condition For process evaluation a stable condition is required Therefore the controller waits until the process has reached a stable condition after self tuning start The rest condition is considered being reached when the process value oscillati on is smaller than 0 596 of r n L H r n L L Set point reserve After having come to rest with 0 correcting variable or with L n the controller requires a sufficient set point reserve for its self tuning attempt in order to avoid overshoot Sufficient set point reserve inverse controller with process value lt set point 10 of 5 F H 5 1 direct controller with process value set point 10 of SPH B HL 0 3 5 3 Self tuning start Self tuning start can be locked via BlueControl engineering tool P L oe The operator can start self tuning at any time For this keys and A must be pres
34. mber was defined via BlueControl and the safety lock is open but no operating level was blocked enter the correct pass number when prompted in A wrong pass number aborts the reset action n Pury v The copy procedure LC ur Y can take some seconds Now the transmitter is In normal operation 56 Operating KS4x 1 Index 0 9 2 point correction 4 A Alarm handling 18 19 B BlueControl 49 Bus interface Technical Data 52 C Calibration level AL 41 43 Certifications uw 4b zum a 53 Configuration examples 2 point controller 3l 3 point controller 32 3 point stepping controller 33 Continuous controller 34 D Y Offcontroller 35 Measured value output 36 signaller 30 Configuration level Configuration parameters 22 28 Parameter survey 21 Connecting diagram ooa 6 Connecting examples di2 3 2 wire transmitter supply 8 INP2 current transformer 7 OUTI 2 heating cooling 7 OUT3 as logic output 8 OUT3 transmitter supply 8 RS485 interface 9 Control inputs dil di2 di3 Technical data a 2 4 amp 4 51 Current signal measuring range 51 D Digital inputs dil di2 di3 Configuration 26 Technical data 2 51 E Environmental conditions 53 Equipment 50 Error list
35. more than one signal 1s linked to one output the signals are OR linked Each of the 3 li mit values L n 1 L nd has 2 trigger points H x Max and L x Min which can be switched off individually parameter UF F Switching difference H4 5x of each limit value is adjustable Alarm handling 18 Operating KS4x 1 Operation D Operaing principle absolut alarm Operating principle relative alarm Lt F E Lot a E a U normally closed an F HGu x Bhcb 1 normally open L anf U uE X 70 86 E The variable to be monitored can be selected seperately for each alarm via configuration The following variables can be monitored process value control deviation xw process value set point control deviation xw suppression after start up or set point change e effective set point Weff correcting variable y controller output Operating KS4x 1 19 Alarm handling Operation If measured value monitoring alarm status storage is chosen Lanf L in rne x the alarm relay remains switched on until the alarm is resetted in the error list L in 1 3 1 3 8 Operating structure After supply voltage switch on the controller starts with the operating levels The controller status is as before power off gt gt 3 Sec rere A level At PRr level the right decimal point of the upper display line 1s it continuously Lanr l
36. n 40 je Calibration level wwe 41 Programmer sse lt lt PRY 0 5 aw 309 w w o3 44 DENT Timer h h h 1 h s s s s s s s s s 9535244 46 8 1 Setting up the timer 46 8 1 1 Operating modes s s s s s s s s s ea 46 8 1 2 Tolerance band now GH s s s s s s s s s s s s HH 47 8 1 3 Timer start ee 47 8 1 4 Signalend beats 91 He Xx 48 Determining the timerrun time 48 Starting the timer 2 2 eee 48 BlueControl 2 s s s s s s s s s s s s e s e s 49 WMOESIONS 4 S 9 3 9 909 9 4 4 Q J Q s a 99 Q X S 9 9 Q 50 Technical data 51 SIE T uz ss uuo eee 3 S 9 EE ae he ee eS 55 Resetting to factory setting a 56 4 Operating KS4x 1 Mounting Mounting Front view KS41 1 96 3 78 Front view KS42 1 96 3 78 Safety switch For access to the safety switches the controller must be withdrawn from the hou sing Squeeze the top and bottom of the front bezel between thumb and forefinger and pull the controller firmly from the housing 10V e mA Pt right nb closed 9 Q Factory setting O Default setting display of all levels suppressed password PASS HF F Safety switch 10V mA Pt always in position left o
37. nF scaling of input and display values at parameter setting level 1s required Specifi cation of the input value for lower and higher scaling point 1s In the relevant elec trical unit mA V mA V phys quantity 5 3 1 Input AF 1 Parameters mb ty lu nH and Hu H are only visible if Lanr nl fi Lar c i 1S chosen LSEMP Inputsignal kt nhi uH _ T 20mA 0 ay 20 ay 30 2m 4 329m 4 a 3 aw nv o aw J aw 10V a TOS 2 any 0 HT y In addition to these settings ni and 1 nH 1 can be adjusted in the range 0 20mA 0 10V determined by selection of St MP For using the predetermined scaling with thermocouple and resistance thermometer Pt100 the settings for nL and U uL 1 and Tor nit and Lio must have the same value Input scaling changes at calibration level page 41 are displayed by input scaling at parameter setting level After calibration reset JF F the scaling parameters are reset to default 5 3 2 Input n P L SEMP Inpusigal nig Butg nH2 fug 0 20mA 0 Jj a 20 a 0 50mA 0 y any S S any In addition to these settings ni c and n H C can be adjusted in the range 0 20 50mA determined by selection of 5 E HP Input scaling 40 Operating KS4x 1 Calibration level is only visible if L anr nB Larr l RA Calibration level L HL M
38. nd the deci mal point 0 1 minutes 6 seconds Alternatively the timer run time can be determined directly at extended opera ting level chapter 8 3 8 3 Starting the timer Dependent of configuration the timer start 1s as follows bya positive flank at one of digital inputs R R dil 3 f A by pressing key by switching on the controller power On R Ada by changing the timer run time EE 1 gt 0 UL _ extended operating level ET e via the serial interface Display Run LED timer is not running yet timer 1s running off timer is off timer has elapsed E n d and setpoint are deletion of n d display by pressing any displayed alternately ke With active timer the time can be adjusted by changing parameter EE at extended operating level Determining the timer run time 48 Operating KS4x 1 BlueControl BE BlueControl BlueControl is the projection environment for the BluePort controller series of PMA The following 3 versions with graded functionality are available FUNCTIONALITY MINI BASIC EXPERT parameter and configuration setting yes yes yes controller and loop simulation yes yes yes download trnsfer of an engineering to the controller yes yes yes online mode visualization SIM only yes yes defining an application specific linearization yes yes yes configuration in the extended operating level yes yes yes upload reading an engineering from the controller SIM
39. nfiguration of setpoint processing set point controller can be switched over to external set point gt Luwi AFE l 2 timer mode 1 bandwidth controlled switched off at the end timer mode 2 bandwidth controlled set point remains active at the en imer mode 3 switched off at the end 5 imer mode 4 set point remains active at the end timer mode 5 switch on dela 7 timer mode 6 set point switch over 0 9999 Timer tolerance band for timer mode 1 2 and 6 The timer start setpoint b ti s when process value I 2 A Y Off or 2 point controller with partial full load switch over 3 2 x PID 3 point and continuous 4 3 point stepping controller Manual operation permitted fyes seealso ROG JARA o direct e g cooling o 0 0 00000000 Behaviour at sensor break O WER 0 0 00 000 00 00 0 y mean output The maximum permissible output can be adjusted with parameter H n m To prevent determination of inadmissible values mean value formation is only if the control deviation is lower than parameter L H n rnb 199 99 XO low limit range of control rni H 1999 9999 X100 high limit range of contro 000 AdtO Optimization of T1 T2 only visible with BlueControl EE Ft ce CA e Z t e Q aiL and r nit are indicating the range of control on which e g the self tuning 1s refering Configuration 22 Operating KS4x 1 Configurat
40. nt polarity sign can change Operating KS4x 1 45 Timer S Timer 8 1 Setting up the timer 8 1 1 Operating modes 6 different timer modes are available to the user The relevant timer mode can be set via parameter SPF n inthef anf menu gt page 21 Mode I After timer start control 1s to the adjusted set point The timer E 5 P runs as soon as pe SP tbe 0 0 0 0 the process value enters or pity the band iP LN b D ame So 2 around the set point x tk T i rs peu Ed blinks blinks timer elapse the on returns to 4 Lnd and the set point are displayed alternate k ly in the lower display line Start Ear Mode 2 Mode 2 corresponds to mode 1 except that control is continued with the relevant set point after timer E 5 P elapse Mode 3 After timer start control 1s to the adjusted set point The timer 5 5 starts immediately after switch over After timer elapsing the 31 controller switches off E n d and the set point are displayed alternately in the bottom display line Mode 4 Start Ear Mode 4 corresponds to mode 3 except that control is continued with the relevant set point after timer 5 P 1 elapse Mode 5 delay The timer starts immediately The controller output remains on Ye After timer 6 5 H elapse control vus with the adjusted set point s N WE run P WS S bliniks p E blinks Setting up the timer 46 Operating KS4x 1 Time
41. out overshoot The following parameters are optimized when self tuning Parameter set 1 D L ri Proportional band 1 heating in engineering units e g C Integral time 1 heating in s only unless set to UF F Derivative time 1 heating in s only unless set to UF F Minimum cycle time heating in s only unless AdtO was set to no self tuning during configuration by means of BlueControl rc I I I I I pe LC ems e m L _ C C Proportional band 2 cooling in engineering units e g C Integral time 2 cooling in s only unless set to UF F Derivative time 2 cooling in s only unless set to OF F Minimum cycle time 2 cooling in s only unless AdtO was set to no self tuning during configuration by means of BlueControl pe Tr EJ Pa P mr me 3 5 1 Preparation for self tuning e Adjust the controller measuring range as control range limits Set values c nL and c nH to the limits of subsequent control Configuration Controller lower and upper control range limits LanF Lntr rnhiL and r n L H e Determine which parameter set shall be optimized see tables above 3 5 2 Self tuning sequence The controller outputs 0 correcting variable or AL a and waits until the process is at rest see start conditions on page 8 Subsequently a correcting variable step change to 100 1s output The contro
42. output gt od Operating KS4x 1 91 Configuration examples Configuration level 4 4 3 3 point controller relay amp relay 100 Uuc e O gt T lt set point controller 3 point controller 2xPID action inverse e g heating applications action U ut i direct control output Y1 active control output Y2 not active action Huk e direct control output Y not active control output Y2 active 1 9999 proportional band 1 heating in units of phys quantity e g C 0 1 9999 proportional band 2 cooling in units of phys quantity e g C Dae Dea 4 gt me k LA rm P ae l Z al r L FP L T L C Se Q D gt a 7 NNS m L Lud px EI bn ad puo me mi L _ KMC lt a ond lt m L em em Q me DI gt E NS L ERES K rom P B w puo P P a NR L L e C N x x a XC a C in ES p gt mi gt Des L Cr m CCP am DuC am dd in Cw a a a L x md LA A m a p C 999 9999 set point limit low Tor Weff 1999 9999 set point limit high for Weff tet 1 9999 integral time 1 heating in sec kee 1 9999 derivative time 2 cooling in sec Edi 1 9999 integral time 1 heating in sec kde 1 9999 derivative time 2 cooling in sec Ed 0 4 9999 min cycle time 1 heating Ec 0 4
43. p 14 jp ma a aaa For direct signaller action the controller action must be changed lank intrer LAck IF well process value b H pes E 1 UU UU setpoint BU Ont 0 000 00 00 00 00 02 00 00 04 00 output gt T L 1L IL TL R R T Tj Configuration examples 30 Operating KS4x 1 Configuration level 4 4 2 2 point controller inverse XC T lt h anF Lntr LL L LL C set point controller 2 point controller PID inverse action e g heating applications action Link i direct control output Y1 active 1 9999 proportional band 1 heating in units of phys quantity e g C m ar Dew gt DEM GA Se deae Pa Pa Ln rm P dm q CUm qu pu C P se Gme ss C ie P mi Dui ee C3 x E n h Lt LLL t dup REP ap C 7 C am aa gt ar am NS De A gt mp x ss Gum C LI LI m LI sa ED Gum O lt ket 1 9999 integral time heating in sec Edi 1 9999 derivative time 1 heating in sec Ed 0 4 9999 min cycle time 1 heating Para SEER SPL 1999 9999 set point limit low for Weff SPH 1999 9999 set point limit high for Weff For direct action the controller action must be changed Cant intr LAck w eff 100 00 setpoint 50 000 lt lt process value 0 000 00 42 30 00 43 00 00 43 30 00 44 00
44. r Mode 6 After set point switch over b P P g control is to 3P c The timer k A F starts EZ XN when the process value enters the adjusted q U UU ecce pA aan band around the set point x 5P z the Tos E nd After time elapse the controller returns to 5 P KB bine np t nd and the set point are displayed alternate ly in the lower display line Start ron 8 1 2 Tolerance band Timer modes 1 2 and 6 are provided with a freely adjustable tolerance band The tolerance band around the set point can be adjusted via parameter R E in the Lank menu x P bk page 21 8 1 3 Timer start Various procedures for starting the timer are possible 4 A c switch over via digital input SP SPe sw tch over via digital input Pressing key E E extended operating Serial interface 1f provided L when using a digital input adjust parameter d Fn c key Binchion x no effect Operating KS4x 1 47 Setting up the timer Timer 6 1 4 Signal end If one of the relays shall switch after timer elapse parameter t ini i and in verse action 0 8 c E i must be selected for the relevant output UUE d Huk inthe Lanf menu page 25 26 If direct action is selected the rele vant output signals the active timer 8 2 Determining the timer run time The timer run time can be determined via parameter 5 inthe PAr A menu The timer run time must be specified in minutes with one digit behi
45. r output y2 continuous 3 Jjpocsvalu 00 0000 O 4 JJjefct veset point We O 5 control deviation xw process value set point Forcing OUT3 only visible with BlueControl No forcing Forcing via serial interface Method of operation and usage of output Uut 1 to Huk i Is more than one signal chosen active as source those signals are OR linked Description Default Local Remote switching Remote adjusting of all values by front keys is blocke ee no function switch over via interface is possible DU W O O DI only visible with OPTION mE E NN 4 D1 only vsiblewith OPTION witehing to second setpointSP2 0 9 no function switch over via interface is posible T 3 JD oo 3 DD mlWsbew hOPTION I 3 D1 only visible with OPTION Configuration 26 Operating KS4x 1 C r yo t2 c e lt e Name Value range Default active s DU e e lt CD gt no function switch over via interface Is possible always activated manual station gt Automatic manual switching DD only visible with OPTION E no function switch over via interface is possible E DD only visible with OPTION DD only visible with OPTION no function switch over via interface is possible E DD only visible with OPTION DD only visible with OPTION O t EN O D O
46. r right Leaving the safety switch open may lead to faulty functions a Caution The unit contains ESD sensitive components Operating KS4x 1 5 Electrical connections Electrical connections 2 1 Connecting diagram Option e 39 GGG oQ G Safety switch mA V in position left Dependent of order the controller is fitted with e flat pin terminals 1 x 6 3mm or 2 x 2 8mm to DIN 46 244 or screw terminals for 0 5 to 2 5mm 2 2 Terminal connection Power supply connection See chapter 11 Technical data Connection of input INPI Input for variable x1 process value thermocouple resistance thermometer Pt100 Pt1000 KTY current 0 4 20mA voltage 0 2 10V ao amp Connecting diagram 6 Operating KS4x 1 Electrical connections Connection of input INP2 Heating current input 0 50mA AC or in put for ext set point 0 4 20mA Q INP2 current tansformer Connection of input dil Digital input configurable as switch or push button Connection of outputs OUTI2 G Relay outputs 250V 2A normally open with common contact connection Connection of output OUT3 Q a relay 250V 2A potential free changeover contact universal output b current 0 4 20mA c voltage 0 2 10V d transmitter supply e logic 0 20mA 0 12V Connection of inputs di2 3 option Digital inputs 24VDC external galvani cally 1solated configurable as
47. rating KS4x 1 Start at set point Heating power Y is switched off 69 If the change of process value X was constant during one minute and the control deviation is gt 10 of SPH SPL U the power is switched on At the reversal point the self tu ning attempt is finished and control to set point W is using the new para meters Three point controller The parameters for heating and coo ling are determined in two attempts The heating power is switched on At reversal point 1 heating para meters hi kil ko land k are determined The process value is lined out to the set point Q The cooling power is switched on At reversal point 2 parameters Phe k te Operation t 100 v 0 start gt 1 Q lt reversal point LET blinks X RA lt reversal point 1 t 100 Y 0 100 stat gt OQ reversal point 2 NX L4 WALES S N Te lt B J E Bs 8 R P VS U NS PEIS LJ 3 d Lu and E are determined and the self tuning attempt is finished Control to set point W is using the new parame ters 3 6 Manual tuning The optimization aid should be used with units on which the control parameters shall be set without self tuning For this the response of process variable x after a step change of correcting va riable y can be used Frequently plotting the complete response curve 0
48. rd must be OX h aneec Fault cabling Check INP1 connection sr ern sm n bling 00 cabling Check INP connection POL INPIpolaritverror Faulty cabling cabling Reverse INPI polarit Sensor break INP2 Sensor defective Replace INP2 sensor Faulty cabling heck INP2 connection emi Tee L 45 E cabling S INP2 connection POL2 IINP2polaity Faulty cabling cabling Reverse INP2 Reverse INP2 polarity Heating current alarm Heating current circuit Check heating current circuit HCA interrupted I lt HL M or I gt If necessary replace heater band N L H dependent of configuration Heater band defective Heating current short Current flow in heating Check heating current circuit M M If necessary replace solid state relay SSR defective Maintenance manager Error list 12 Operating KS4x 1 Operation Control loop alarm Input signal defective or not Check heating or cooling circuit LOOP connected correctly Check sensor and replace it 1f necessary Output not connected Check controller and switching device correct x tuning heating j See Self tuning heating error see Self tuning heating error status alarm status ADAH self tuning heating See Self tuning cooling error see Self tuning cooling error status alarm cooling status EN exceeded _ UR er feme exceeded exceeded lid ee NN Message hours reached digital ouputs cycles reached Saved alarms
49. sed simul taneously The AdA LED starts blinking The controller outputs 0 or to waits until the process 19 at rest and starts self tuning AdA LED lit permanently After successful self tuning the AdA LED 1s off and the controller continues operating with the new control parameters 3 5 4 Self tuning cancellation By the operator Self tuning can always be cancelled by the operator For this press and key simultaneously With manual automatic switch over configured via E key self tuning can also be canceled by actuating Ej key The controller continues operating with the old parameters in automatic mode n the first case and in ma nual mode in the second case By the controller If the Err LED starts blinking whilst self tuning 1s running successful self tuning is prevented due to the control conditions In this case self tuning was cancelled by the controller Dependent of control type the output status 1s 3 pnt stepping controller actuator 1s closed 0 output e 2 pnt 3 pnt continuous controller If self tuning was started from the automatic mode the controller output 1s 0 With self tuning started from manual mode the controller output is Y2 Operating KS4x 1 19 Self tuning Operation 3 5 5 Acknowledgement procedures in case of unsuccessful self tuning 1 Press keys and A simultaneously The controller continues controlling using the old parameters in automatic mode The Err LED continues
50. stallation of the controller a switch or a circuit breaker must be used and signified The switch or circuit breaker must be installed near by the controller and the user must have easy access to the controller COMMISSIONING Before instrument switch on check that the following information 1s taken into account e Ensure that the supply voltage corresponds to the specifications on the type label e All covers required for contact protection must be fitted e Ifthe controller is connected with other units in the same signal loop check that the equipment in the output circuit 1s not affected before switch on If necessary suitable protective measures must be taken e The unit may be operated only in installed condition e Before and during operation the temperature restrictions specified for controller operation must be met SHUT DOWN For taking the unit out of operation disconnect it from all voltage sources and protect it against accidental operation If the controller is connected with other equipment in the same signal loop check that other equipment in the output circuit is not affected before switch off If ne cessary suitable protective measures must be taken 54 Operating KS4x 1 Safety hints MAINTENANCE REPAIR AND MODIFICATION The units do not need particular maintenance N Warning When opening the units or when removing covers or components live parts and terminals may be exposed Before starting this work
51. t end set point 4 200 PEL 0 999 Segment time 4 min Q if 5751 57 nV UFF k following parameters are not shown P U If segment end set point F F then the segment time is not visible FEAT 29 999 input value for the lowersealingpoint 9 duk t 1999 9999 Displayed value for the lower scalingpoint 0 nit 1999 9999 Input value for the upper scaling point 70 duhi 1999 9999 Displayedvalueforthelowerscalingpoint 20 EF i 99 999 Filtertimeconstant OS tonic 1999 9999 Inputvalueforthelowerscalingpoint T duk 1999 9999 Displayedvalueforthelowerscalingpoint 0 nic 1999 9999 Inputvaluefortheupperscalingpoint 50 Uu 1999 9999 Displayedvaluefortheupperscalingpoint 50 t 1999 9999 Lowerlmit o 0 FA 199 999 Uppelimt j 10 HNR TT 0 99 Hymsslmtl SS tc 1999 9999 Lowelimt2 HEE Fhe 1909 999 Upperlimit2 4 OFO Kanae 0 999 JHysersislimt2 i OO td 199 999 Lowerlimit3 HEE Md 1999 9999 Upprlimt3 4 Uff 35 3 0 999 JHysresislimt3 o S _ HEM 1999 9999 Heatcurrntcontrollimit A 5 Resetting the controller configuration to factory setting Default chapter 12 1 page 56 Operating KS4x 1 39 Parameters Parameter setting level 5 3 Input scaling When using current or voltage signals as input variables for T nF or
52. tion Thermocouples Table 1 page 53 Input resistance gt 1 MQ Effect of source resistance 1 uV Q2 Cold junction compensation Maximal additional error E UK Sensor break monitoring sensor current lt 1 mA Configurable output action Resistance thermometer Table 2 page 53 Connection 2 or 3 wire Lead resistance max 30 Ohm Input circuit monitor break and short circuit Special measuring range BlueControl engineering tool can be used to match the input to sensor KI Y 11 6 characteristic is stored in the controller Physical measuring range 0 4500 Ohm Linearization segments 16 Current and voltage signals Table 3 page 53 Span start end of anywhere within measuring Span range scaling selectable 1999 9999 Linearization 16 segments adaptable with BlueControl Decimal point adjustable Input circuit monitor 12 596 below span start 2mA 1V SUPPLEMENTARY INPUT INP2 Resolution 14 bits scanning cycle 100 ms Accuracy 0 5 9o Heating current measurement via current transformer Accessory equipment Operating KS4x 1 Technical data Measuring range 0 50mA AC scaling adjustable 1999 0 000 9999 A Current measuring range Technical data as for INP1 CONTROL INPUT DI1 Configurable as switch or push button Connection of a potential free contact suitable for switching dry circuits switched voltage 25V Current 50 uA CONTROL INPUTS DI2 DI3 OP
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