West Control Solutions KS 40-1 User Manual

PMA Prozeß- und Maschinen-Automation GmbH

r

Universal controller for burners

KS40-1 burner

KS40-1 burner

expertline

KS40-1 burne

Operating manual

English

9499-040-66011

Valid from:8473

Description of symbols
in the text: on the device:

g General information a Follow the operating instructions
a General warning
l Attention: ESD-sensitive devices

© PMA Prozeß- und Maschinen-Automation GmbH • Printed in Germany (0207)

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 Prozeß- und Maschinen Automation

P.O.Box 310229

D-34058 Kassel

Germany

Contents

1 Mounting .............................. 5

2 Electrical connections ....................... 6

3 Operation.............................. 7

3.1 Front view.............................. 7

3.2 Operating level ........................... 8

3.3 Self-tuning ............................. 10

3.4 Manual tuning ........................... 11

3.5 Operating structure ........................ 13

4 Configuration level ........................14

4.1 Configuration with qUIC ..................... 14

4.2 Configuration without qUIC ( qUIC= OFF) ..........18

4.3 Configuration survey:....................18

5 Parameter setting level ...................... 24

5.1 Input scaling (only visible with qUIC = OFF)..........26

6 Calibration level ......................... 27

7 Programmer ........................... 30

8 Technical data .......................... 32

9 Safety hints ............................ 36

9.1 Resetting to factory setting .................... 38

3 KS40-1 burner

KS40-1 burner 4

1 Mounting

Mounting

(0.4")

10

118

SP.X

F

96 (3.78")

KS 40-1 burner

48 (1.89")

(4.65")

126

125

min.48

SG

Ada

Err

Loc

Safety switch

Ü

(1.89")

1..10

(0.04..0.4")

+0,6

45

+0.02

(1.77" )

10V i mA/Pt

or:

+0,8

+0.03

92

max.

60°C

0°Cmin.

(3.62" )

max.
95% rel.

%

Loc 10V mA/Pt

Loc 10V mA/Pt

Loc 10V mA/Pt

Ü

*

*

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For access to the safety switches, the controller must be withdrawn from the hou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 i mA/Pt mA/Pt 1 Thermocouple / Pt100 or transducer at InP.1

10V Pressure transmitter (0..10V) at InP.1

Loc open Access to the levels is as adjusted by means of

BlueControl (engineering tool)

closed 1 all levels accessible wihout restriction

1 Factory setting 2 Default setting: display of all levels

suppressed, password PASS = OFF

2

-

a

l

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

Caution! The unit contains ESD-sensitive components.

5 KS40-1 burner

Electrical connections

g

O

2 Electrical connections

di2

di3

U(+)

t

P

1

(2)

3

4

5

6

10

11

12

13

14

15

A

1

2

3

4

5

6

7

8

9

L
N

OUT1
OUT2

OUT3

g

+

+

90...250V

gh

c

100%

0%

++

10V *

0%

--

100%

1

3

2

INP2

2

20mA **

1

INP1

ption

abbc

edf

* Safety switch INP1 (mA i 10V) in position 10V
** Safety switch INP1 (mA i 10V) in position mA/Pt

Connection of input INP1

Input for variable x1 (process value)

a thermocouple
b resistance thermometer (Pt100/ Pt1000/ KTY/ ...)

c Transducer 50-30-50 W
d voltage (0/2...10V)
e pressure transmitter (3-wire connection)
f pressure transmitter (2-wire connection)
g current (0/4...20mA)

Connection of input INP2

See input INP1.

Connection of inputs di2/di3

Digital input di2 for external switching between SP and SP.2 (SP/SP2).
Digital input di3 for external switching between 3-point-stepping controller and
on/off controller (DPS/SG).

KS40-1 burner 6

125

126.

SP.x

SG

Err

Ada

123OK

3

1

2

3

7

!

"

4

8

5
6

9

0

$

%

è

§

&

KS 40-1

burner

3 Operation

3.1 Front view

Operation

1 Status of switching outputs

OuT.1... 3

2 Lit with limit value 1 not

exceeded

3 Process value display
4 Controller works as on/off

controller

5 Self-tuning active
6 Entry in error list
7 Set-point, controller output
8 Enter key:

calls up extended operating
level / error list

9 Up/down keys:

changing the set-point or the
controller output value

0 Set-point SP.2 or SP.E is

effective

! Set-point gradient effective
" Manual mode

§ Function key
$ Manual-automatic-mode

switching ( " )

% PC connection for BlueControl

(engineering tool)

& Signalization

PArA level (burns)
ConF level (blinks)

g

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

Front view 7 KS40-1 burner

Operation

A

M

l

3.2 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.

time

out

utomatic

126

125

È
Ì

Ù

i

Ò

Ò

i

anua

126

y21

È
Ì

Ù

time

out

-

126

y21

only

display

Ù

126

125

È
Ì

Ù

Extended operating level

time

out

Errorliste (if error exists)

126

FbF.1

KS40-1 burner 8 Operating level

display

switching

Err

126

2

Err

Maintenance manager / Error list

With one or several errors, the extended operating level
always starts with the error list. Signalling an actual en
try in the error list (alarm, error) is done by the Err LED

-

SP.X

in the display. To reach the error list press Ù twice.

Err LED status Signification Proceed as follows

blinks Alarm due to existing error

lit Error removed,

Alarm not acknowledged

off No error,all alarm entries deleted

Determine the error type in the error list via the error number

­Remove the error

­Acknowledge the alarm in the error list pressing key È or Ì

­The alarm entry was deleted.

-

Error list:

Operation

126

125

SG

Ada

Err

Name

E.1

E.2

FbF.1

/ 2

Sht.1

/ 2

POL.1

LooP

AdA.H

LiM.1/

2 / 3

Inf.1

Description Cause Possible remedial action

Internal error,
cannot be
removed

Internal error,
can be reset

Sensor break
INP1 / 2

Short circuit
INP1 / 2

INP1 polarity
error

Control loop
alarm (LOOP)

Self-tuning
heating alarm
(ADAH)

stored limit
alarm1/2/3

time limit value
message

E.g. defective EEPROM

-

- e.g. EMC trouble - Keepmeasurement andpower supply cables in

- Sensor defective

- Faulty cabling

- Sensor defective

- Faulty cabling

- Faulty cabling - Reverse INP1 polarity

- Input signal defective or not
connected correctly

-

Output not connected correctly

-

See Self-tuning heating error
status

-

adjusted limit value1/2/3
exceeded

-

adjusted number of operating
hours reached

Contact PMA service

-

- Return unit to our factory

separate runs

- Ensure that interference suppression of contactors is
provided

- Replace INP1 / 2 sensor

- Check INP1 / 2 connection

- Replace INP1/ 2 sensor

- Check INP1 / 2 connection

- Check heating or cooling circuit

-

Check sensor and replace it, if necessary

-

Check controller and switching device

-

see Self-tuning heating error status

-

check process

-

application-specific

Operating level 9 KS40-1 burner

Operation

Error status (error status 3 - 9 only with error AdA.H / AdA.C ):

Error status Signification

0 No error/message not visible, except with acknowledgement
1 Stored error Change to error status 0 after acknowledgement in error list
2 Existing error Change to error status 1 after error removal

3

Faulty control action Re-configure controller (inverse i direct)

4

No response of process
variable

5

Low reversal point Increase ( ADA.H) max. output limiting Y.Hi or decrease

6

Danger of exceeded
set-point (parameter
determined)

7

Output step change too
small (dy > 5%)

8

Set-point reserve too
small

9

Impulse tuning failed The control loop is perhaps not closed: check sensor, connections and process

The control loop is perhaps not closed: check sensor, connections and process

( ADA.C) min. output limiting Y.Lo
If necessary, increase (inverse) or reduce (direct) set-point

Increase ( ADA.H) max. output limiting Y.Hi or reduce
( ADA.C) min. output limiting Y.Lo

Increase set-point (invers), reduce set-point (direct) or increase set-point
range (r PArA / SEtp / SP.LO and SP.Hi )

3.3 Self-tuning

After starting by the operator, the controller makes a self-tuning attempt. The
controller uses the process characteristics for quick line-out to the set-point wit­hout overshoot.

g

ti and td are taken into account only, if they were not set to
OFFpreviously.

Self-tuning start

The operator can start self-tuning at any time. For this, keys Ù and È must be
pressed simultaneously. The AdA LED starts blinking.
The controller outputs 0% or Y.Lo, waits until the process is at rest and starts
self-tuning (AdA LED lit permanently).

The self-tuning attempt is started when the following prerequisite is met:

The difference between process value i set-point must be ³ 10% of the

w

set-point range ( SP.Hi - SP.LO) (with inverse action: process value smaller
than set-point, with direct action: process value higher than set-point).

After successful self-tuning, the AdA-LED is off and the controller continues
operating with the new control parameters.

Self-tuning cancellation by the operator:

Self-tuning can always be cancelled by the operator. For this, press Ù and È
key simultaneously. The controller continues operating with the old parameters in
automatic mode in the first case and in manual mode in the second case.

KS40-1 burner 10 Self-tuning

Operation

3

Self-tuning cancellation by the controller:

If the Err LED starts blinking while self-tuning is running, successful self-tuning
is prevented due to the control conditions. In this case, self-tuning was cancelled
by the controller. The controller switches off its outputs (controller output 0%).

Acknowledgement procedures in case of unsuccessful self-tuning:

1. Press keys Ù and È simultaneously:

The controller continues controlling using the old parameters in automatic
mode. The Err LED continues blinking, until the self-tuning error was
acknowledged in the error list.

2. Press key Ù :

Display of error list at extended operating level. After acknowledgement of
the error message, the controller continues control in automatic mode
using the old parameters.

Cancellation causes:

r page 9: "Error status self-tuning heating ( ADA.H) and cooling ( ADA.C)"

Examples for self-tuning attempt 3-point-stepping controller

After the start (1) the controller
closes the actuator (2 Out.3).

W
X

When the difference between
process value and set-point is
big enough (3), the changing of
the process value is monitored
for 1 min. (4). Afterwards the
actuator is opened (5 Out.1).
If the reversal point is reached

1 min

(6) or there are made enough
measurements, the parameters
are detected and are adopted.

1

2

4

5

6

3.4 Manual tuning

t

t

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 to
100%) is not possible, because the process must be kept within defined limits.

Manual tuning 11 KS40-1 burner

Operation

y

Values Tgand x

(step change from 0 to 100 %) or Dt and Dx (partial step re

max

sponse) can be used to determine the maximum rate of increase v

100%

Y

h

0%

x

X

max

Tg

y =correcting variable

Y

= control range

h

Tu = delay time (s)

Tg = recovery time (s)

X

V

= maximum process value

max

{{x

=

t

max

Xmax

=

Tg

Tu

= max. rate of increase of process value

{t

max

{X

-

.

t

t

The control parameters can be determined from the values calculated for delay
time T

, maximum rate of increase v

u

, control range Xhand characteristic K ac-

max

cording to the formulas given below. Increase Xp, if line-out to the set-point os­cillates.

Parameter adjustment effects

Parameter Control Line-out of disturbances Start-up behaviour

Pb1 higher increased damping slower line-out slower reduction of duty cycle

lower reduced damping faster line-out faster reduction of duty cycle

td1 higher reduced damping faster response to disturbances faster reduction of duty cycle

lower increased damping slower response to disturbances slower reduction of duty cycle

ti1 higher increased damping slower line-out slower reduction of duty cycle

lower reduced damping faster line-out faster reduction of duty cycle

Formulas

K = Vmax * Tu controller behavior Pb1 [phy. units] td1 [s] ti1 [s]
With 2-point and

3-point controllers,
the cycle time must be

adjusted to
t1 / t2 £ 0,25 * Tu

PID 1,7*K 2*Tu 2*Tu
PD 0,5 * K Tu OFF
PI 2,6 * K OFF 6*Tu
PKOFF OFF
3-point-stepping 1,7 * K Tu 2 * Tu

KS40-1 burner 12 Manual tuning