Thank you very much for buying an Universal Controller KS 45.
The universal controllers KS 45 are suitable for precise, cost-efficient contol tasks in all industrial applications.
For that you can choose between simple on/off-, PID- or motorstepping control.
The process-value signal is connected via an universal input. A second analog input can be used for heating-current
measurement or as external setpoint input.
The KS 45 has at least one universal input and two switching outputs. Optionally the controller can be fitted with an
universal output or with optocoupler outputs. The universal output can be configured as continuous output with current
or voltage, for triggering solid state relays or for transmitter supply.
Galvanic isolation is provided between inputs and outputs as well as from the supply voltage and the communication
interfaces.
Applications
The KS 45 as universal controller can be utilized in many applications, e.g.:
...
Furnaces
w
Burners and boilers
w
Dryers
w
Climatic chambers
w
Heat treatment
w
Sterilizers
w
Oxygen-control
w
As a positioner
w
General
At-a-glance survey of advantages
Compact construction, only 22,5 mm wide
Clips onto top-hat DIN rail
Plug-in screw terminals or spring clamp connectors
Dual-line LC display with additional display elements
Process values always in view
Convenient 3-key operation
Direct communication between rail-mounted transmitters
Universal input with high signal resolution (>14 bits) reduces stock keeping
Universal output with high resolution (14 bits) as combined current / voltage output
Quick response, only 100 ms cycle time, i.e. also suitable for fast signals
Logical linking of digital outputs, e.g. for common alarms
Second analog input for ext. setpoint, heating current or as universal input
Further documentation for universal controller KS 45:
–
Data sheet KS 459498 737 48513
–
Operating note KS 459499 040 71541
–
Interface description9499 040 72011
KS 455
General
1.1Application in thermal plants
In many thermal plants, only the use of approved control instruments is permissible.
There is a KS 45 version (KS45-1xx-xxxxx-Dxx) which meets the requirements as an electronic temperature controller
(TR, type 2.B) according to DIN 3440 and EN 14597.
This version is suitable for use in heat generating plants, e.g. in
building heating systems acc. to DIN EN 12828 (formerly DIN 4751)
•
large water boilers acc. to DIN EN 12953-6 (formerly DIN 4752)
•
heat conducting plants with organic heat transfer media acc. to DIN 4754
•
oil-fired plants to DIN 4755
•
…
Temperature monitoring in water, oil and air is possible by means of suitable approved probes.
Application in thermal plants6KS45
2Safety 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.
Safety hints
a
a
The unit is intended exclusively for use as a measurement and control instrument in technical
installations.
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 installation of the controller a switch or a circuit-breaker must be used and signified. The switch or cir
cuit-breaker must be installed near by the controller and the user must have easy access to the controller.
COMMISSIONING
Before instrument switch-on, check that the following information is taken into account:
Ensure that the supply voltage corresponds to the specifications on the type label.
•
All covers required for contact protection must be fitted.
•
If the controller is connected with other units in the same signal loop, check that the equipment in
•
the output circuit is not affected before switch-on. If necessary, suitable protective measures must
be taken.
The unit may be operated only in installed condition.
•
Before and during operation, the temperature restrictions specified for controller operation must
•
be met.
-
a
a
Warning
The ventilation slots must not be covered during operation.
The measurement inputs are designed for measurement of circuits which are not connected directly with
the mains supply (CAT I). The measurement inputs are designed for transient voltage peaks up to 800V
against PE.
SHUT-DOWN
For taking the unit out of operation, disconnect it from all voltage sources and protect it against accidental operation.
If the controller is connected with other equipment in the same signal loop, check that other equipment in the output
circuit is not affected before switch-off. If necessary, suitable protective measures must be taken.
KS 457
Safety hints
2.1MAINTENANCE, REPAIR AND MODIFICATION
The units do not need particular maintenance.
There are no operable elements inside the device, so the user must not open the unit
Modification, maintenance and repair work may be done only by trained and authorized personnel. For this purpose,
the PMA service should be contacted.
a
l
g
Warning
When opening the units, or when removing covers or components, live parts and terminals may be exposed.
Connecting points can also carry voltage.
Caution
When opening the units, components which are sensitive to electrostatic discharge (ESD) can be exposed.
The following work may be done only at workstations with suitable ESD protection.
Modification, maintenance and repair work may be done only by trained and authorized personnel. For this purpose,
the PMA service should be contacted.
You can contact the PMA-Service under:
PMA Prozeß- und Maschinen-Automation GmbH
Miramstraße 87
D-34123 Kassel
The cleaning of the front of the controller should be done with a dry or a wetted (spirit, water)
handkerchief.
2.3Spare parts
As spare parts für the devices the following accessory parts are allowed:
DescriptionOrder-No.
Connector set with screw terminals9407-998-07101
Connector set with spring-clamp terminals9407-998-07111
Bus connector for fitting in top-hat rail9407-998-07121
MAINTENANCE, REPAIR AND MODIFICATION8KS45
3Mounting
A
.
Mounting
bmessungen / dimensions
56
22.5
(0,87”)
max.
117.5 (4,63”)
55°C
-10°Cmin.
111 (4, 37 ”)
max.
95% rel.
7
Klemme /
1516
8
terminal
17
12
18
Klemme /
terminal
%
Montage / mounting
5.5
(0,20”)
4
3
2.3
(0,08”)
click
99 (3,90”)
Demontage / dismantling
1
11 1 2
14
13
g
a
a
a
l
a
a
The unit is provided for vertical mounting on 35 mm top-hat rails to EN 50022.
If possible, the place of installation should be exempt of vibration, aggressive media (e.g. acid, lye), liquid, dust or
aerosol.
The instruments of the rail line series can be mounted directly side by side. For mounting and dismounting, min. 8 cm
free space above and below the units should be provided.
For mounting, simply clip the unit onto the top-hat rail from top and click it in position.
To dismount the unit, pull the bottom catch down using a screwdriver and remove the unit upwards.
Universal Controller KS 45 does not contain any maintenance parts, i.e. the unit need not be opened by the
customer.
The unit may be operated only in environments for which it is suitable due to its protection type.
The housing ventilation slots must not be covered.
In plants where transient voltage peaks are susceptible to occur, the instruments must be equipped with
additional protective filters or voltage limiters!
Caution! The instrument contains electrostatically sensitive components .
Please, follow the instructions given in the safety hints.
To maintain contamination degree 2 acc. to EN 61010-1, the instrument must not be installed below
contactors or similar units from which conducting dust or particles might trickle down.
KS 459
Mounting
3.1Connectors
g
a
The four instrument connectors are of the plug-in type. They plug into the housing from top or bottom and click in posi
tion (audible latching). Releasing the connectors should be done by means of a screwdriver.
Two connector types are available:
Screw terminals for max. 2,5 mm2conductors
•
Spring-clamp terminals for max. 2,5 mm2conductors
•
Before handling the connectors, the unit must be disconnected from
the supply voltage.
Tighten the screw terminals with a torque of 0,5 - 0,6 Nm.
With spring-clamp terminals, stiff and flexible wires with end crimp can be
introduced into the clamping hole directly. For releasing, actuate the (or
ange) opening lever.
Contact protection: Terminal blocks which are not connected should remain in the socket.
-
-
Connectors10KS 45
4Electrical connections
.
4.1Connecting diagram
Electrical connections
7
2
5
1
KS45-1xY-xxxxx-xxx
=0,1,2,3
Y
(mV)
a
e
b
c
d
INP2
INP1
OUT3
PWR
a
b
c
d
e
f
g
h
i
k
j
90...260V AC
24V AC/DC
5
1
mV
Logic
11
15
L
8
76
4
3
3
2
V
V
12
13
14
18
17
16
N
b
a
di1
OUT1
OUT2
RGND
Data A
Data B
RS 485
KS45-1xY-xxxxx-xxx
=4,5
Y
1234
3
9
0
1234
11 12 13 14
11 12 13 14
15 16 17 18
15 16 17 18
AC / DC
8
INP2
INP1
3
2
top
RGND
Data A
Data B
6
PWR
1
5
1
2
mV
24VDC
12
11
15
16
L
N
90...260V AC
24V AC/DC
b
a
8
76
3
3
13
17
di1
4
V
OUT1
14
OUT2
18
OUT3
4
4.2
a
g
Terminal connections
Faulty connection might cause destruction of the instrument !
1 Connecting the supply voltage
Dependent on order
90 … 260 V ACterminals: 15,16
•
24 V AC / DCterminals: 15,16
•
For further information, see section "Technical data"
Instruments with optional system interface:
Energization is via the bus connector of field bus coupler or power supply module. Terminals 15, 16 must
not be used.
Opto-coupler outputs with shared positive control voltage.
OUT1terminals: (11), 12, 13
•
OUT2terminals: (11), 12, 14
•
! Connecting relay output OUT3 (optional)
Relay output max. 250V/2A as nomally open contact.
OUT3terminals: 17, 18
•
Terminal connections12KS 45
4.3Connecting diagram
The instrument terminals used for the engineering can be displayed and printed out via BlueControlÒ( menu File \ Print
preview - Connection diagram).
Example:
Connecting diagram
Connector 1
Pin
Name
Connector 2
Pin
Name
Description
Process value x1
Description
Signal limit 1, signal INP1 fail
Electrical connections
Heating current input
Switch-over to SP2
Connector 3
Pin
Name
Controller output Y2
Controller output Y1
Description
KS 4513Connecting diagram
Electrical connections
2
4.4Connection examples
Example: INP2 with current trans- former and
SSR via opto-coupler
L
5
7
6
INP2
INP1
PWR
PWR
8
di1
4
3
2
1
SSR
_
+
OUT1
14
11
13
12
15
16
OUT2
18
17
N
Connection example: KS 45 and TB 45
L
L1
Fuse
INP2
INP1
KS 45
5
1
7
6
8
di1
4
3
2
Fuse
contactor
Example: heating / cooling OUT 1 /OUT2
L
5
7
6
1
11
15
5
1
2
12
16
TB 45
6
2
8
di1
4
3
+
14
13
OUT2
18
17
OUT1
7
8
di1
4
3
Resetbutton
N
Fuse
INP2
INP1
PWR
PWR
temperature limiter
INP1
heating
SSR
+
_
OUT3
PWR
PWR
Logic
14
11
13
12
18
15
17
16
+
+
PWR
PWR
14
11
13
12
18
15
17
16
LC
N1
N2
Example: RS 485 interface with RS 485-RS 232 converter
See documentation 9499-040-72011
Master z.B. / e.g.
Converter RS 232-RS 485
RGND
3
LT 1
Data A
Data B
2
Data A
Data B
(ADAM-4520-D)
LT 1
DATA+ 1
DATA-
TX+
TXRX+
RX-
(R)+Vs
(B)GND 10
(RS-485)
(RS-422)
Connection examples14KS 45
4.5Hints for installation
Measurement and data lines should be kept separate from control and power supply cables.
w
Sensor measuring cables should be twisted and screened, with the screening connected to
w
earth.
External contactors, relays, motors, etc. must be fitted with RC snubber circuits to manufacturer
w
specifications.
The unit must not be installed near strong electric and magnetic fields.
w
The temperature resistance of connecting cables should be selected in accordance with the
w
local conditions.
Electrical connections
a
a
a
a
4.5.1cULus approval
The unit is not suitable for installation in explosion-hazarded areas.
Faulty connection can lead to the destruction of the instrument.
The measurement inputs are designed for measurement of circuits which are not connected directly with
the mains supply (CAT I). The measurement inputs are designed for transient voltage peaks up to 800V
against PE.
Please, follow the instructions given in the safety hints.
For compliance with cULus regulations, the following points must be taken into account:
Use only copper (Cu) wires for 60 / 75 °C ambient temperature.
q
q
The connecting terminals are designed for 0,5 – 2,5 mm2Cu conductors.
q
The screw terminals must be tightened using a torque of 0,5 – 0,6 Nm.
q
The instrument must be used exclusively for indoor applications.
q
For max. ambient temperature: see technical data.
q
Maximum operating voltage: see technical data.
KS 4515Hints for installation
Operation
5Operation
.
5.1Front view
1Line 1: process value display
2Display 2: setpoint /output value/ unit-display / extended
operating level / errolist / values from Conf- and
PArA-level special functions as A-M, Func, run, AdA
3operating mode “manual”
4Error list (2 x ô ), e.g.
· Fbf. xsensor fault INP. X
· sht. xshort circuit INP. X
· Pol. xwrong polarity INP. X
· Lim. xlimit value alarm
· ...
5Increment key
6Enter key to select extended operating level or error list
7Status indicator LEDs
·green:limit value 1 OK
·green blinking:no data exchange with bus coupler
(only on instruments with optional
system interface)
8Display elements, active as bars
9Status of switching output OUT1 active
0Status of switching output OUT2 active
!Decrement key
§PC connection for the BlueControl
Ò
engineering tool
g
+
Front view16KS 45
In the first LCD-display line the measured value is shown. The second LCD-line normally shows the
setpoint. When changing over to the parameter setting, configuration or calibration level and at the
extended operating level, the parameter name and value are displayed alternately.
§ : To facilitate withdrawal of the PC connector from the instrument, please, press the cable left.
5.2Operating structure
The instrument operation is divided into four levels:
Operation
450.3
450.0
äüüü
ME
1
2
The access to the parameter, configuration and calibrating level can be disabled using the following two methods:
w
3s
ô
Level disabling by adjustment in the engineering tool (IPar, ICnf, ICal). Display of disabled levels
is suppressed.
450.3
PARA
äüüü
ME
1
2
450.3
CONF
äüüü
1
ô
ME
2
450.3
CAL
äüüü
1
ô
ME
2
450.3
END
äüüü
1
2
ô
ME
PASS
PASS
PASS
ô
Operating level
Parameter level
Configuration level
Calibrating level
The access to a level can be disabled by entry of a pass number (0 … 9999). After entry of the
w
adjusted pass number, all values of the level are available.
With faulty input, the unit returns to the operating level.
Adjusting the pass number is done via BlueControl
Individual parameters which must be accessible without pass number, or from a disabled
parameter level, must be copied into the extended operating level.
Factory-setting:
all levels are accessible without restrictions,
pass number PASS = OFF
5.3Behaviour after supply voltage switch-on
After switching on the supply voltage, the instrument starts with the operating level.
The operating status is as before power-off.
If the device was in manual mode, when switching off the power-supply, it also starts up in manual mode with output
value Y2.
Ò
.
PASS
KS 4517Operating structure
Operation
ü
5.4Displays in the operating level
5.4.1Display line 1
The displayed value, also named process value, is shown in the first display line. This value is used as controlled value
(variable). It results from the configuration C.tYP. (also see chp./page 7-22.)
5.4.2Display line 2
The value to be displayed continuously in the second LCD line can be selected from different values via the
BlueControl
Normally the internal setpoint SP is set.
Ò
engineering tool.
1
450.3
450.0
äüüü
2
ME
1
g
g
By deleting the individual settings for display 2, it is resetted to setpoint display. Reset to display of the
engineering unit is possible by deleting the entry for line 2.
With faulty input values, signals dependent on the inputs (e.g. Inp1, Inp2, display value, Out3) also indicate FAIL.
5.4.3Switch-over with the enter-key
By using the enter-key, different values can be called in display 2. Every time you press the enter key, the display
jumps to the next feature as shown below.
2
450.3
mAn
ääüü
2
ME
1
1Default settings as setpoint
2Display of operating mode
automatic/manual
1
Displaying the defined display 2 value (via BlueControlÒ).
Standard setting is the internal setpoint
2
Displaying the output value, e.g. Y57
3
Calling up the error list, if messages are supplied.
If there is more than one message with every push of
the enter key the next message is displayed.
4
Calling up the extended operating level, if messages
are supplied.
If there is more than one message with every push of
the enter key the next message is displayed.
5
Returning to the original displayed value.
If for 30 s no key is pushed, the display automatically
returns to the origin.
1
2
3
4
5
ô
ô
ô
ô
ô
450.3
450.0
äüüü
ME
1
2
450.3
Y57
ä üüü
ME
1
2
450.3
FbF.1
ä üüü
ME
1
2
450.3
L.1
ä üüü
ME
1
2
450.3
450.0
äüüü
ME
1
2
ô
ô
Displays in the operating level18KS 45
5.5Extended operating level
The operation of important or frequently used parameters and signals can be allocated to the extended operating level.
This facilitates the access, e.g. travelling through long menu trees is omitted, or only selected values are operable, the
other data of the parameter level are e.g. disabled.
Display of the max. 8 available values of the extended operating level is in the second LCD line.
The content of the extended operating level is determined by means of the BlueControl
select entry "Operation level" in the "Mode" selection menu. Further information is given in the on-line help of the engi
neering tool.
450.3
äüüü
1
2
ô
ûC
M
E
Ò
engineering tool. For this,
Press key ô to display the first value of the extended
operating level (after display of error list, if necessary).
The selected parameters can be changed by
pressing keys Ì and È .
Operation
-
450.3
H.I
äüüü
2
ME
1
ô press to display the next parameter
450.3
500.0
äüüü
2
ME
1
ô
450.3
L.I
äüüü
2
ME
1
ô return to normal display after the last parameter
450.3
100.0
äüüü
2
ME
1
ô
Unless a key is pressed within a defined time (timeout = 30 s), the operating level is displayed again.
Extended operating level19KS 45
Operation
1
2
5.6Special change-over functions
In order to operate switch-over or -on functions needed more often via front, there are special functions available.
A-M
•
Switch-over automatic / manual-operation
ProG
•
starting / stopping the programmer
Func
•
Selection of different switching signals
Via the engineering tool BlueControl
function can be adjusted in the operating mode (sig
nals/logic). It can be assigned permanently to display 2
or the extended operating level.
5.6.1Automatic / manual switch-over
Ò
the desired
-
Between automatic and manual operation can be
switched with the A-M function via front.
g
g
5.6.2ProG - start programmer
g
For A-M function handling, the switch-over
source must be set to “Interface only” (Conf /
LoGI / mAn = 0).
Manual operation ist selected via the È - key. The
display element M is activated.
If adjustment of the output value is allowed
(Conf / Cntr / mAn = 1), the output value is displayed, otherwise display element (M) blinks.
The Ì - key switches to automatic operation. The function can be taken into the extended operating level, or perma nent in display 2.
If the programmer function is activated, (Conf / Cntr / SP.Fn = 1/9), with this function the programmer can
be started (run) or stopped (OFF) via front.
With the È - key the programm is started and stopped with the Ì - key.
After the end of a programm the stop function (OFF) must be selected before the programm can be started
again.
450.3
Auto
äüüü
2
ME
1
2
450.3
mAn
дьдьь
1
ME
5.6.3Func - switching function
The switching function Func takes the tasks of a function key. One or more signals switching at the same time, can be
selected via configuration (Conf / LOGI/x=5)ausgewählt werden.
The switching function is set to on (= 1) via the È - key and to OFF (= 0) via Ì - key.
+
Example: The setpoint range adjustable by the user is limited from 20 to 100. Nevertheless it shall be possible to
switch off the controller via front. This can be done by assigning Conf / LOGI / C.oFF= 5 and taking the
Func - value into the extended operating level.
g
Special change-over functions20KS 45
Function Func is not suitable for timer activation.
5.7Selecting the units
The unit to be displayed is determined via configuration D.Unt.
With selection “1 = temperature unit” , the displayed unit is determined by configuration Unit with the relevant
conversions for Fahrenheit and Kelvin.
By selecting D.Unt = 22, display of any max. 5-digit unit or text can be determined.
Operation
1
4.5
kWh
1Unit (example): kilowatt hour
2Text (example): TAG no.
äüüü
2
ME
2
1
450.3
TI451
äüüü
2
ME
1
For permanent display the value signals/other/D.Unt must be set in the mode "operating level" via the engineering
g
tool.
Selecting the units21KS 45
Functions
6Functions
.
The signal data flow of transmitter KS 45 is shown in the following diagram:
6.1Linearization
The input values of input INP1 or INP2 can be linearized via a table.
By means of tables, e.g. special linearizations for thermocouples or other non-linear input signals, e.g. a container
filling curve, are possible.
Table “ Lin” is always used with sensor type S.TYP= 18: "Special thermocouple" in INP1 or INP2, or if linearization
S.Lin = 1: “Special linearization” are adjusted.
w
w
w
Non-linear signals can be linearized using up to 16 segment points. Each segment point comprises an input ( In.1
… In.16) and an output (Ou.1 … Ou.16). These segment points are interconnected automatically by straight
lines. The straight line between the first two segment points is extended downwards and the straight line between the
two highest segment points is extended upwards, i.e. a defined output value for each input value is provided.
With an In.x value switched to OFF, all further segments are switched off.
+
g
Required: Condition for the input values is an ascending order.
In.1 < In.2 < ...< In.16.
For linearization of special thermocouples, the ambient temperature range should be defined exactly,
becauseit is used to derive the internal temperature compensation.
The input signals must be specified in mV, V, mA, % or Ohm dependent on input type.
For special thermocouples (S.tYP = 18), specify the input values in mV, and the output values in
the temperature unit adjusted in U.LinT .
For special resistance thermometer (KTY 11-6) (S.tYP = 23), specify the input values in Ohm, and
the output values in the temperature unit adjusted in U.LinT.
See also page 60.
Linearization22KS 45
Ou.16
.
.
.
.
.
.
Ou.1
In
1In
1
Functions
g
The same linearization table is used for input 1 and input 2.
6.2Input scaling
Scaling of input values is possible. After any linearization, measurement value correction is according to the offset or
two-point method.
g
When using current or voltage signals as input variables for InP.x, the input and display values should
be scaled at the parameter level. Specification of the input value of the lower and upper scaling point is in
units of the relevant physical quantity.
Example for mA/V
mA / V
phys.
quantity
OuH.x
OuL.x
InL.x
InH.x
phys. quantity
mA/V
g
KS 4523Input scaling
Parameters InL, OuL, InH and OuH are visible only with ConF / InP / Corr = 3 selected.
Parameters InL and InH determine the input range.
Example with mA:
InL= 4 and InH = 20 means that measuring from 4 to 20 mA is required (life zero setting).
Loading...
+ 53 hidden pages
You need points to download manuals.
1 point = 1 manual.
You can buy points or you can get point for every manual you upload.