West Control Solutions KS 42-1 User Manual

PMA Prozeß- und Maschinen-Automation GmbH

Industrial controller KS 40-1,

KS41-1 and KS42-1

KS40-1

KS41-1

KS42-1

Operating manual

9499-040-62711

KS40-1

KS41-1

KS42-

English

Valid from: 8499

ATTENTION!

Mini Version and Updates on

or on PMA-CD

www.pma-online.de

BlueControl

More efficiency in engineering,

more overview in operating:

The projecting environment for the BluePort

controllers

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

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

2.1 Connecting diagram......................... 6

2.2 Terminal connection ........................ 6

3 Operation ............................. 10

3.1 Front view ............................. 10

3.2 Behaviour after power-on ..................... 11

3.3 Operating level .......................... 11

3.4 Maintenance manager / Error list ................12

3.5 Self-tuning ............................. 14

3.5.1 Preparation for self-tuning........................14

3.5.2 Self-tuning sequence ..........................14

3.5.3 Self-tuning start ..........................15

3.5.4 Self-tuning cancellation ........................15

3.5.5 Acknowledgement procedures in case of unsuccessful self-tuning . 16

3.5.6 Examples for self-tuning attempts ..................16

3.6 Manual tuning ........................... 17

3.7 Alarm handling .......................... 18

3.8 Operating structure ........................ 20

4 Configuration level ........................21

4.1 Configuration survey ...................... 21

4.2 Configuration ........................... 22

4.3 Set-point processing ........................ 29

4.4 Configuration examples ...................... 30

4.4.1 On-Off controller / Signaller (inverse) .................30

4.4.2 2-point controller (inverse) .......................31

4.4.3 3-point controller (relay & relay) ....................32

4.4.4 3-point stepping controller (relay & relay) ...............33

4.4.5 Continuous controller (inverse) .....................34

4.4.6 D - Y - Off controller / 2-point controller with pre-contact .....35

4.4.7 KS4x-1 with measured value output ..................36

Operating KS4x-1 3

5 Parameter setting level ...................... 37

5.1 Parameter survey ......................... 37

5.2 ................................... 37

5.3 ................................... 37

5.4 Parameters ............................. 38

5.5 Input scaling ............................ 40

5.5.1 Input Inp.1 ...............................40

5.5.2 Input InP.2 ............................40

6 Calibration level ......................... 41

7 Programmer .......................... 44

8 Timer ............................... 46

8.1 Setting up the timer ........................ 46

8.1.1 Operating modes ............................46

8.1.2 Tolerance band .............................47

8.1.3 Timer start ................................47

8.1.4 Signal end ................................48

8.2 Determining the timer run-time ..................48

8.3 Starting the timer ........................ 48

9 BlueControl ............................ 49

10 Versions .............................. 50

11 Technical data .......................... 51

12 Safety hints ............................ 55

12.1 Resetting to factory setting .................... 56

4 Operating KS4x-1

1 Mounting

SP.X

run

Err

Ada

SP.x

run

Err

Adada

SP.x

run

Err

Ada

Mounting

(0.4")

118

96 (3.78")

KS 40-1 universal

48 (1.89")

(4.65")

126

125

min.48

Loc

Safety switch

(1.89")

1..10

(0.04..0.4")

+0,6

+0.02

(1.77" )

10V i mA/Pt

or:

Front view KS41-1

max.

60°C

max. 95% rel.

0°Cmin.

48 (1.89")

+0.03

+0,8

(3.62" )

126.

125

KS 41-1 universal

96 (3.78")

Front view KS42-1

126.

Loc 10V mA/Pt

(3.78")

KS 42-1 universal

125

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 i mA/Pt right 1 Current signal / Pt100 / thermocouple at InP.1

left Voltage signal 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

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.

Operating KS4x-1 5

Electrical connections

2 Electrical connections

2.1 Connecting diagram

di2

di3

Modbus RTU

RXD-B

RGND

DATA B

DATA A

RS485 RS422

GND

RXD-A

TXD-B

TXD-A

Option

(2)

(16)

L N

Logic

90...250V

24V AC/DC

OUT1 OUT2

OUT3

INP2

di1

0..10 V*

INP1

* Safety switch mA i V in position left

Dependent of order, the controller is fitted with :

flat-pin terminals 1 x 6,3mm or 2 x 2,8mm to DIN 46 244 or

screw terminals for 0,5 to 2,5mm²

2.2 Terminal connection

Power supply connection 1

See chapter 11 "Technical data"

Connection of input INP1 2

Input for variable x1 (process value)

a thermocouple b resistance thermometer (Pt100/ Pt1000/ KTY/ ...) c current (0/4...20mA) d voltage (0/2...10V)

Connecting diagram 6 Operating KS4x-1

Electrical connections

SSR

Connection of input INP2 3

Heating current input (0...50mA AC) or in

put for ext. set-point (0/4...20mA)

Connection of input di1 4

Digital input, configurable as switch or push-button

Connection of outputs OUT1/2 5

Relay outputs 250V/2A normally open with common contact connection

Connection of output OUT3 6

a relay (250V/2A), potential-free

changeover contact

universal output

b current (0/4...20mA) c voltage (0/2...10V) d transmitter supply e logic (0..20mA / 0..12V)

Connection of inputs di2/3 7 (option)

Digital inputs (24VDC external), galvanically isolated, configurable as switch or push-button

3 INP2 current tansformer

Logic

5 OUT1/2 heating/cooling

Connection of output U

8 (option)

Supply voltage connection for external ener gization

Connection of bus interface 9 (option)

RS422/485 interface with Modbus RTU protocol

Operating KS4x-1 7 Terminal connection

Electrical connections

SSR

78 di2/3, UT2-wire transmitter supply

Option

+24VDC

17,5V 22mA

5mA

(2)

(16)

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

OUT3

6 OUT3 transmitter supply

13V

22mA

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

Logic

Series connection

I =22mA

max

12V

Parallel connection

I =22mA

max

12V

Terminal connection 8 Operating KS4x-1

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

Electrical connections

R = 120...200 OhmT

RGND connection optional

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

KS4x-1 connecting example:

RGND RGND

DATA B

DATA A

(16)

DATA B

DATA A

KS 40-1

Logic

fuse

SSR

contactor

fuse

heating

(16)

RGND

DATA B

DATA A

(16)

R=100 Ohm

converter

RS485-RS232

max. 1000m

”Twisted Pair”

TB 40-1

Temperature limiter

R = 120...200 OhmT

fuse

reset

1 TB 40-1 Temperature limiter

Standard version (3 relays): TB40-100-0000D-000

other versions on requestr

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

KS 40-1 universal

125

126.

SP.x

run

Err

Ada

123OK

7 8

KS 42-1 universal

125

126.

SP.x

run

Err

Ada

KS42-1

KS 41-1 universal

125

126.

SP.x

run

Err

Ada

KS41-1

KS40-1

3 Operation

3.1 Front view

LED colours:

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

1 Status of switching outputs

OuT.1... 3

2 Lit with limit value 1 ( PArA /

Lim ) not exceeded

3 Process value display 4 Set-point, controller output 5 Signals ConF and PArA level 6 Programmer or timer running 7 Self-tuning active 8 Entry in error list 9 Set-point SP.2 or SP.E is

effective

0 Set-point gradient effective ! Manual/automatic switch-over:

Off: Automatic On: Manual

(changing possible)

Blinks: Manual

(changing not possible (r ConF/ Cntr/ MAn)

" Enter key:

calls up extended operating level / error list

§ Up/down keys:

changing the set-point or the controller output value

$ Manual mode /spec. function

(® ConF / LOGI )

% PC connection for

BlueControl (engineering tool)

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

Front view 10 Operating KS4x-1

3.2 Behaviour after power-on

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

3.3 Operating level

Operation

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

126

anua

126

y21

126

È Ì

time

out

y21

only

display

125

È Ì

Extended operating level

time

out

Errorliste (if error exists)

126

FbF.1

display

switching

Err

126

Err

Operating KS4x-1 11 Behaviour after power-on

Operation

3.4 Maintenance manager / Error list

With one or several errors, the extended operating level always starts with the error list. Signalling an actual entry in the error list (alarm, error) is done by the Err LED in the display. To reach the error list press Ù twice.

SP.x

Err LED status Signification Proceed as follows

blinks

(Status 2)

lit

(Status 1)

off

(Status 0)

Alarm due to existing error

Error removed, Alarm not acknowledged

No error, all alarm entries deleted

Determine the error type in the error list via the

error number

-Change to status 1 after error removal.

Acknowledge the alarm in the error list pressing

key È or Ì The alarm entry was deleted (Status 0).

-Not visible except when acknowledging

126

125

run

Ada

Err

Name

E.1

E.2

E.4

FbF.1

Sht.1

POL.1 FbF.2

Sht.2

POL.2

HCA

SSr

Error list:

Description Cause Possible remedial action

Internal error, cannot be removed

Internal error, can be reset

Hardware error - Codenumber and hardware

Sensor break INP1

Short circuit INP1

INP1polarity error Sensor break INP2

Short circuit INP2

INP2 polarity Heating current alarm

(HCA)

Heating current short circuit (SSR)

- E.g. defective EEPROM - Contact PMA service

- Return unit to our factory

- e.g. EMC trouble - Keep measurement and power supply cables in separate runs

- Ensure that interference suppression of contactors is provided

- Contact PMA service

are not identical

- Elektronic-/Optioncard must be exchanged

Sensor defective

Faulty cabling

Sensor defective

Faulty cabling

Sensor defective

Faulty cabling

Sensor defective

Faulty cabling

Heating current circuit interrupted, I< HC.A or I>

Replace INP1 sensor

Check INP1 connection

Replace INP1 sensor

Check INP1 connection

Reverse INP1 polarity

Replace INP2 sensor

Check INP2 connection

Replace sensor INP2

Check INP2 connection

Reverse INP2 polarity

Check heating current circuit

If necessary, replace heater band

HC.A (dependent of configuration)

Heater band defective

Current flow in heating circuit with controller off

SSR defective

Check heating current circuit

If necessary, replace solid-state relay

Maintenance manager / Error list 12 Operating KS4x-1

Operation

Name

LooP

AdA.H

AdA.C

LiM.1

Lim.2

Lim.3

Inf.1

Inf.2

Description Cause Possible remedial action

Control loop alarm (LOOP)

Input signal defective or not

connected correctly Output not connected

Check heating or cooling circuit

Check sensor and replace it, if necessary

Check controller and switching device

correctly

Self-tuning heating alarm

See Self-tuning heating error

status

see Self-tuning heating error status

(ADAH) Self-tuning heating

alarm cooling

See Self-tuning cooling error

status

see Self-tuning cooling error status

(ADAC) stored limit alarm 1

adjusted limit value 1

check process

exceeded

stored limit alarm 2

adjusted limit value 2

check process

exceeded

stored limit alarm 3

adjusted limit value 3

check process

exceeded

time limit value message

duty cycle message (digital ouputs)

adjusted number of operating

hours reached

adjusted number of duty

cycles reached

application-specific

Error status

0 3 4

Saved alarms (Err-LED is lit) can be acknowledged and deleted with the digital input di1/2/3 or the Ò-key. Configuration, see page 27: ConF / LOGI / Err.r

If an alarm is still valid that means the cause of the alarm is not removed so far (Err-LED blinks), then other saved alarms can not be acknowledged and deleted.

Self-tuning heating ( ADA.H) and cooling ( ADA.C) error status:

Description Behaviour No error Faulty control action Re-configure controller (inverse i direct) No response of process

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

Danger of exceeded set-point (parameter determined)

Output step change too small (dy > 5%)

Set-point reserve too small Increase set-point (invers), reduce set-point (direct)

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

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

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

or increase set-point range (r PArA / SEtp / SP.LO and SP.Hi )

Operating KS4x-1 13 Maintenance manager / Error list

Operation

3.5 Self-tuning

For determination of optimum process parameters, self-tuning is possible. After starting by the operator, the controller makes an adaptation attempt, where by the process characteristics are used to calculate the parameters for fast line-out to the set-point without overshoot.

The following parameters are optimized when self-tuning: Parameter set 1:

Pb1 - Proportional band 1 (heating) in engineering units [e.g. °C] ti1 - Integral time 1 (heating) in [s] r only, unless set to OFF td1 - Derivative time 1 (heating) in [s] r only, unless set to OFF

t1 - Minimum cycle time 1 (heating) in [s] r only, unless Adt0 was set to

“no self-tuning” during configuration by means of BlueControl

Pb2 - Proportional band 2 (cooling) in engineering units [e.g. °C] ti2 - Integral time 2 (cooling) in [s] r only, unless set to OFF td2 - Derivative time 2 (cooling) in [s] r only, unless set to OFF t2 - Minimum cycle time 2 (cooling) in [s] r only, unless Adt0 was set to

“no self-tuning” during configuration by means of BlueControl

3.5.1 Preparation for self-tuning

Adjust the controller measuring range as control range limits. Set values

rnG.L and rnG.H to the limits of subsequent control. (Configuration

rControllerrlower and upper control range limits)

ConFrCntrr rnG.L and rnG.H

Determine which parameter set shall be optimized (see tables above).

3.5.2 Self-tuning sequence

®.

The controller outputs 0% correcting variable or Y.Lo and waits, until the process is at rest (see start-conditions on page 8).

Subsequently, a correcting variable step change to 100% is output. The controller attempts to calculate the optimum control parameters from the

process response. If this is done successfully, the optimized parameters are taken over and used for line-out to the set-point.

With a 3-point controller, this is followed by “cooling”. After completing the 1st step as described, a correcting variable of -100% (100%

cooling energy) is output from the set-point. After successfull determination of the “cooling parameters”, line-out to the set-point is using the optimized parameters.

Self-tuning 14 Operating KS4x-1

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 ± 0,5% of (rnG.H - rnG.L).

Set-point reserve

After having come to rest with 0% correcting variable or with Y.Lo, the controller requires a sufficient set-point reserve for its self-tuning attempt, in order to avoid overshoot.

Sufficient set-point reserve:

inverse controller:(with process value<set-point-(10% of SP.Hi - SP.LO) direct controller:(with process value>set-point+ (10% of SP.Hi - SP.LO)

3.5.3 Self-tuning start

Operation

3.5.4 Self-tuning cancellation

Self-tuning start can be locked via BlueControl (engineering tool) ( P.Loc).

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).

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

By the operator:

Self-tuning can always be cancelled by the operator. For this, press Ù and È key simultaneously. With manual-automatic switch-over configured via Ò key, self-tuning can also be canceled by actuating Ò key. The controller continues operating with the old parameters in automatic mode in the first case and in ma nual mode in the second case.

By the controller:

If the Err LED starts blinking whilst self-tuning is running, successful self-tuning is prevented due to the control conditions. In this case, self-tuning was cancelled by the controller. Dependent of control type, the output status is:

3-pnt. stepping controller:

actuator is closed (0% output) 2-pnt./ 3-pnt./ continuous controller:

If self-tuning was started from the automatic mode, the controller output is 0%. With self-tuning started from manual mode, the controller output is Y2.

SP.x

126

125

run

Ada

Err

Operating KS4x-1 15 Self-tuning

Operation

3.5.5 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 Ò (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 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 13: "Error status self-tuning heating ( ADA.H) and cooling ( ADA.C)"

3.5.6 Examples for self-tuning attempts

(controller inverse, heating or heating/cooling)

Start: heating power switched on

Heating power Y is switched off (1). When the change of process value X was constant during one minute (2), the power is switched on (3). At the reversal point, the self-tuning attempt is finished and the new parameter are used for controlling to set-point W.

Start: heating power switched off

The controller waits 1,5 minutes (1). Heating power Y is switched on (2). At the reversal point, the self-tuning attempt is finished and control to the set-point is using the new parameters.

100%

Star t r

start r

blinks

t reversal point

blinks

Self-tuning 16 Operating KS4x-1

Operation

Start: at set-point

Heating power Y is switched off (1).

blinks

t reversal point

If the change of process value X was constant during one minute and the control deviation is > 10% of SP.Hi SP.LO (2), the power is switched on (3). At the reversal point, the self-tu ning attempt is finished, and control to set-point W is using the new para

100%

start r

meters.

Three-point controller

The parameters for heating and coo

ling are determined in two attempts. The heating power is switched on (1). At reversal point 1, heating para meters Pb1, ti1, td1 and t1

+100%

Y0%

-100%

start r

t reversal point 1

t reversal point 2

are determined. The process value is lined out to the set-point (2). The cooling power is switched on (3). At reversal point 2, parameters Pb2, ti2, td2 and t2 are determined and the self-tuning attempt is finished. Control to set-point W is using the new parameters.

3.6 Manual tuning

The optimization aid should be used with units on which the control parameters shall be set without self-tuning. For this, the response of process variable x after a step change of correcting 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. Values T sponse) can be used to determine the maximum rate of increase v

100%

max

and x

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

max

y = correcting variable

= control range

Tu = delay time (s)

Tg = recovery time (s) X

= maximum process value

max

{{x

max

Xmax

= max. rate of

increase of process value

Operating KS4x-1 17 Manual tuning

Operation

The control parameters can be determined from the values calculated for delay time T cording to the formulas given below. Increase Xp, if line-out to the set-point os cillates.

Parameter adjustment effects

Parameter Control Line-out of disturbances Start-up behaviour

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

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

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

, maximum rate of increase v

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

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

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

, control range Xhand characteristic K ac

max

Formulas

K = Vmax * Tu controller behavior Pb1 [phy. units] td1 [s] ti1 [s]

PID 1,7*K 2*Tu 2*Tu With 2-point and 3-point controllers,

the cycle time must be adjusted to

t1 / t2 £ 0,25 * 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

3.7 Alarm handling

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

Alarm handling 18 Operating KS4x-1

+ 42 hidden pages

West Control Solutions KS 42-1 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual