West Control Solutions KS 45 User Manual

PMA Prozeßund Maschinen-Automation GmbH

Universal controller

KS 45

KS 45

KS 45

Operating manual

					English
					9499-040-71811
	rail line
					valid from: 06/2009

û BlueControl

More efficiency in engineering, more overview in operating:

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indicators and rail line - measuring converters / universal controllers

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Explanation of symbols:

g a l

General information

General warning

Caution: ESD-sensitive components

Caution: Read the operating instructions

Read the operating instructions

+Note

©2004 PMA Prozeßund Maschinen-Automation GmbH Printed in Germany

All rights reserved No part of this document may be reproduced or published in any form or by any means without prior written permission from the copyright owner.

A publication of

PMA Prozeßund Maschinen Automation

P.O.Box 310229

Germany

Content

1.General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.1 Application in thermal plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.Safety hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 MAINTENANCE, REPAIR AND MODIFICATION . . . . . . . . . . . . . . . . . . . . 8

2.2Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3.1 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

4. Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1Connecting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.2 Terminal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.3Connecting diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4.4 Connection examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4.5 Hints for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 4.5.1 cULus approval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

5.Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

5.1	Front view . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2	Operating structure	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

5.3Behaviour after supply voltage switch-on . . . . . . . . . . . . . . . . . . . . . . . 17

5.4 Displays in the operating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.4.1Display line 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.4.2Display line 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5.4.3Switch-over with the enter-key . . . . . . . . . . . . . . . . . . . . . . . . 18

5.5 Extended operating level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.6Special change-over functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.6.1Automatic / manual switch-over. . . . . . . . . . . . . . . . . . . . . . . . 20

5.6.2ProG - start programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.6.3 Func - switching function . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.7Selecting the units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.1Linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.2Input scaling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.2.1Input fail detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.2.2Two-wire measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.3Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.4Substitue value for inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.5Input forcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.6 O2 measurement (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.7Limit value processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.7.1Input value monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.7.2Heating-current alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.7.3Loop-alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.7.4 Monitoring the number of operating hours and switching cycles . . . . . . 29

6.8Analog output (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

6.8.1	Analog output . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . 30
6.8.2	Logic output . . . . . . . . . . . . . . . . . . . .	. . . . . . . . . . . . . . 31
6.8.3	Transmitter power supply . . . . . . . . . . . . .	. . . . . . . . . . . . . . 31

6.8.4Analog output forcing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.9Maintenance manager / error list . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.9.1Error list: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.9.2Error status self-tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

6.10Resetting to factory setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7. Controlling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7.1Setpoint processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

7.1.1Setpoint gradient / ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.1.2Setpoint limitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.1.3Second setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

7.2Configuration examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

7.2.1Signaller (inverse)/ On-Off controller . . . . . . . . . . . . . . . . . . . . . 37

7.2.22-point controller (inverse) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

7.2.33-point controller (relay & relay) . . . . . . . . . . . . . . . . . . . . . . . . 39

7.2.43-point stepping controller (relay & relay) . . . . . . . . . . . . . . . . . . . 40

7.2.5	Continuous controller (inverse) . . . . . . . . . . . . . . . . . . . .	. . . . 41
7.2.6	Y - Off controller / 2-point controller with pre-contact. . . . .	. . . . 42

7.3Self-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.3.1 Preparation for self-tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

7.3.2	Self-tuning sequence	. . . . . . . . . . . . . . . . . . . . . . .	. . . .	.	. 43
7.3.3	Self-tuning start	. . . . . . . . . . . . . . . . . . . . . . . .	. . . .	.	. 44

7.3.4Self-tuning cancellation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

7.3.5Acknowledgement procedures in case of unsuccessful self-tuning . . . . . 44

7.3.6 Examples for self-tuning attempts . . . . . . . . . . . . . . . . . . . . . . 45

7.4 Manual tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

8.Programmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

9. Timer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9.1Setting up the timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9.1.1Operating modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

9.1.2Tolerance band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

9.1.3Timer start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

9.1.4 Signal end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

9.2Determining the timer run-time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

9.3 Starting the timer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

9.4 End / cancelation of the timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

10.Configuration level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

10.1 Configuration survey

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

10.2Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

11.Parameter-level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

11.1Parameter-survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

11.2Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

12.Calibrating-level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

12.1Offset-correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

12.22-point-correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

13.Engineering Tool BlueControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

14.Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

15.Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

16.Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

General

. 1	General
	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-, PIDor 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.:
	w	Furnaces
	w	Burners and boilers
	w	Dryers
	w	Climatic chambers
	w	Heat treatment
	w	Sterilizers
	w	Oxygen-control
	w	As a positioner
	...

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

2-Pt.-, 3-pt.-, motorstepping-, continuous controlling

Customer-specific linearization

Measurement value correction (offset or 2-point)

Self-optimization

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 45		9498 737 48513
–	Operating note KS 45	9499 040 71541
–	Interface description	9499 040 72011

KS 45

5

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 plants

6

KS 45

Safety hints

. 2 Safety hints

a

a

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.

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.

a a

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.

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 45

7

Safety hints

2.1MAINTENANCE, REPAIR AND MODIFICATION

a

l

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.

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.

g You can contact the PMA-Service under:

PMA Prozeßund Maschinen-Automation GmbH

Miramstraße 87

D-34123 Kassel

Tel. +49 (0)561 / 505-1257 Fax +49 (0)561 / 505-1357

e-mail: [e-mail]

2.2Cleaning

g	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:

Description	Order-No.
Connector set with screw terminals	9407-998-07101
Connector set with spring-clamp terminals	9407-998-07111
Bus connector for fitting in top-hat rail	9407-998-07121

MAINTENANCE, REPAIR AND MODIFICATION 8

KS 45

Mounting

. 3 Mounting

Abmessungen / dimensions	(0,20”)
5.5

		7	8	/		3	4
	6		Klemme		2
5				1
			terminal

2.3

(0,08”)

99 (3,90”)

					18		/			14
			16					12
				17	Klemme				13
						terminal11
		15
22.5	111 (4,37”)
(0,87”)	117.5	(4,63”)

max.	55°C	max.
min.	-10°C	95% rel. %

Montage / mounting

click

Demontage / dismantling

1

	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.
g	Universal Controller KS 45 does not contain any maintenance parts, i.e. the unit need not be opened by the
	customer.

a a

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.

a In plants where transient voltage peaks are susceptible to occur, the instruments must be equipped with additional protective filters or voltage limiters!

l

a a

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 45

9

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 mm2 conductors

•Spring-clamp terminals for max. 2,5 mm2 conductors

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.

Connectors

10

KS 45

Electrical connections

. 4 Electrical connections

4.1Connecting diagram

KS45-1xY-xxxxx-xxx	KS45-1xY-xxxxx-xxx
Y = 0, 1, 2, 3	Y = 4, 5

	e a (mV)														1 2 3 4
	b					b				AC / DC				b
	c
						a								a
7	d						3	8	INP2						3
	INP2	5	6	7	8	di1				5	6	7	8	di1

2	INP1	a	1	2	3	4	2	INP1	1	2	3	4
		b
		c				top
		d
						RGND	RGND
		e		mV		Data A	Data A			mV
		f			V	Data B	Data B					V
		g
			Logic			RS 485	6		24VDC
													9
												OUT1
		h
									11	12	13	14
	k	i										OUT2
		j		V				PWR	15	16	17	18
5	OUT3		11	12	13	14			L	N		OUT3	0
							1		90...260V AC				11 12 13 14
			15	16	17	18			24V AC/DC
	PWR												15 16 17 18
						OUT1
			L	N			4
1
			90...260V AC			OUT2
			24V AC/DC

4.2Terminal connections

a Faulty connection might cause destruction of the instrument !

1 Connecting the supply voltage

Dependent on order

•

•

90	… 260 V AC	terminals:	15,16
24	V AC / DC	terminals:	15,16

	For further information, see section "Technical data"
g	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.
	2 Connecting input INP1
	Input for the measurement value
	a	resistance thermometer (Pt100/ Pt1000/ KTY/ ...), 3-wire connection	terminals: 1, 2, 3
	b	resistance thermometer (Pt100/ Pt1000/ KTY/ ...), 4-wire connection	terminals:	2, 3, 5, 6
	c	potentiometer	terminals:	1, 2, 3
	d	current (0/4...20mA)	terminals:	2, 3
	e	voltage (-2,5...115/-25...1150/-25...90/ -500...500mV)	terminals:	1, 2
	f	voltage (0/2...10V/-10...10V/ -5...5V)	terminals:	2, 4
	g	thermocouple	terminals:	1, 3

KS 45

11

Connecting diagram

Electrical connections

3 Connecting input di1

Digital input, configurable as a switch or a push-button.
a	contact input	terminals: 7,8
b	optocoupler input (optional)	terminals: 7,8

4 Connecting outputs OUT1 / OUT2 (optional)

Relay outputs max. 250V/2A NO contacts with a common terminal.

•	OUT1	terminals: 17, 18
•	OUT2	terminals: 17, 14
5 Connecting output OUT3
Universal output
h	logic (0..20mA / 0..10V)	terminals: 11,12
i	current (0...20mA)	terminals: 11,12
j	voltage (0...10V)	terminals: 12,13
k	transmitter power supply	terminals: 11,12

6 Connecting the bus interface (optional exept d)

RS 485 interface with MODBUS RTU protocol

* see interface description MODBUS RTU: (9499-040-72011)

7 Connecting input INP2 (optional exept d)

Input for the second variable INP2.
a	thermocouple	terminals: 5,6
b	resistance thermometer (Pt100/ Pt1000/ KTY/ ...), 3-wire connection	terminals: 2,5,6
c	potentiometer	terminals: 2,5,6
d	current (0/4...20mA)	terminals: 2,6
e	voltage (-2,5...115/-25...1150/-25...90/ -500...500mV)	terminals; 5,6
8 Connection of input INP1 for the version with optional opto-coupler outputs
Input for the measured variable (measurement value).
a	resistance thermometer (Pt100/ Pt1000/ KTY/ ...), 3-wire connection	terminals: 1, 2, 3
c	potentiometer	terminals:	1, 2, 3
d	current (0/4...20mA)	terminals:	2, 3
e	voltage (-2,5...115/-25...1150/-25...90/ -500...500mV)	terminals: 1, 2
f	voltage (0/2...10V / -10...10V / -5...5V)	terminals:	2, 4
g	thermocouple	terminals:	1, 3
9 Connecting INP2 -HC (optional)
Input for heating current
•	Current 0/4...20mA DC and 0 … 50 mA AC	terminals: 5,6

0 Connecting opto-coupler outputs OUT1 / OUT2 (optional)

Opto-coupler outputs with shared positive control voltage.

•

•

OUT1	terminals:	(11), 12, 13
OUT2	terminals:	(11), 12, 14

! Connecting relay output OUT3 (optional)

Relay output max. 250V/2A as nomally open contact.
•	OUT3	terminals: 17, 18

Terminal connections

12

KS 45

Electrical connections

4.3Connecting diagram

The instrument terminals used for the engineering can be displayed and printed out via BlueControl ( menu File \ Print preview - Connection diagram).

Example:

Connecting diagram
Connector 1
Pin Name	Description

Process value x1

Heating current input

Switch-over to SP2

Connector 2

PinName

Connector 3

PinName

Description

Signal limit 1, signal INP1 fail

Controller output Y2

Controller output Y1

Description

KS 45

13

Connecting diagram

Electrical connections

4.4Connection examples

Example: INP2 with current transformer and SSR via opto-coupler

L

Example: heating / cooling OUT 1 /OUT2

L

INP2

5

6

7

8

di1

INP2

5

6

7

8

di1

INP1	1	2	3	4	INP1	1	2	3	4

									+
					SSR
					_
					+
				OUT1
11	12	13	14	OUT2	11	12	13	14	OUT2
PWRPWR 15	16	17	18		PWRPWR 15	16	17	18	OUT1

N

N

Connection example: KS 45 and TB 45

L2

L1

Fuse		KS 45			Fuse	Fuse
INP2 5		6	7	8	di1
INP1	1	2	3	4
					contactor
					heating

SSR

+

_

Logic

+ +

OUT3 11 12 13 14

PWRPWR 15 16 17 18

N1

N2

Example: RS 485 interface with RS 485-RS 232 converter See documentation 9499-040-72011

TB 45 temperature limiter

5 6 7 8 di1

INP1	1	2	3	4

Resetbutton

11 12 13 14

PWRPWR 15 16 17 18 LC

RGND 3

	Data A
LT 1	Data B
	Data A
2	Data B

Master z.B. / e.g. Converter RS 232-RS 485 (ADAM-4520-D)

	DATA+	1
LT 1	DATA-	-(RS
		485)
	TX+
	TX-	(RS
		-
	RX+	422)
	RX-
	(R)+Vs
	(B)GND 10

14

KS 45

Electrical connections

4.5Hints for installation

a

a a

w	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
	earth.
w	External contactors, relays, motors, etc. must be fitted with RC snubber circuits to manufacturer
	specifications.
w	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
	local conditions.

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.

a Please, follow the instructions given in the safety hints.

4.5.1 cULus approval

For compliance with cULus regulations, the following points must be taken into account:

q Use only copper (Cu) wires for 60 / 75 °C ambient temperature.

q The connecting terminals are designed for 0,5 – 2,5 mm 2 Cu 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 45

15

Hints for installation

Operation

. 5

5.1

Operation

Front 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

3

operating mode “manual”

4

Error list (2 x ô ), e.g.

Fbf. x

sensor fault INP. X

sht. x

short circuit INP. X

Pol. x

wrong polarity INP. X

Lim. x

limit value alarm

...

5

Increment key

6

Enter key to select extended operating level or error list

7

Status indicator LEDs

green:

limit value 1 OK

green blinking:no data exchange with bus coupler

(only on instruments with optional

system interface)

red:

limit value 1 active

red blinking: instrument fault, configuration mistake

8 Display elements, active as bars

9 Status of switching output OUT1 active

0 Status of switching output OUT2 active

!Decrement key

§PC connection for the BlueControl engineering tool

g	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.

Front view

16

KS 45

Operation

5.2Operating structure

The instrument operation is divided into four levels:

450.3
4500.		3 s
	ô
äüüü			450.3
1 2 M E					ô		PASS
			PARA
			äüüü
			1 2 M	E

CONF450.3 ô PASS

äüüü

1 2 M E

CAL450.3 ô PASS

äüüü

1 2 M E

END450.3 ô

äüüü

1 2 M E

Operating level

Parameter level

Configuration level

Calibrating level

The access to the parameter, configuration and calibrating level can be disabled using the following two methods:

w	Level disabling by adjustment in the engineering tool (IPar, ICnf, ICal). Display of disabled levels
	is suppressed.
w	The access to a level can be disabled by entry of a pass number (0 … 9999). After entry of the
	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

PASS

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.

KS 45

17

Operating structure

Operation

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 CtYP. . (also see chp./page 7-22.)

5.4.2 Display line 2

The value to be displayed continuously in the second LCD line can be selected from different values via the BlueControl engineering tool.

Normally the internal setpoint SP is set.

	1		2
				1	Default settings as setpoint
	450.3	450.3		2	Display of operating mode
					automatic/manual
	4500.		mAn
	äüüü	ä	äüü
	1 2 M E	1	2 M E
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.

g With faulty input values, signals dependent on the inputs (e.g. Inp1, Inp2, display value, Out3) also indicate FAIL.

5.4.3 Switch-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.

1 Displaying the defined display 2 value (via BlueControl ). Standard setting is the internal setpoint

2 Displaying the output value, e.g. Y 57

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.

1 450.3

4500.

äüüü

1 2 M E

ô

2 450.3

Y57

äüüü

1 2 M E

ô

	3	450.3	ô
		FbF1.

äüüü

1 2 M E

ô

	4	450.3	ô
		L1.

äüüü

1 2 M E

ô

5 450.3

4500.

äüüü

1 2 M E

18

KS 45

Operation

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 engineering tool. For this, 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

ûC

äüüü

1 2 M E

ô

450.3

HI.

äüüü

1 2 M E

ô

450.3

LI.

äüüü

1 2 M E

ô

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 .

450.3

5000.

äüüü

1 2 M E

ô press to display the next parameter

450.3

1000.

äüüü

1 2 M E

ô return to normal display after the last parameter

Unless a key is pressed within a defined time (timeout = 30 s), the operating level is displayed again.

19

KS 45

Operation

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 the desired function can be adjusted in the operating mode (signals/logic). It can be assigned permanently to display 2 or the extended operating level.

5.6.1 Automatic / manual switch-over

	Between automatic and manual operation can be
	switched with the A-M function via front.
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.

1 2

450.3450.3

Auto	mAn
äüüü	дьдьь
1 2 M E	1 2 M E

g	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.
5.6.2		ProG - start programmer
	If the programmer function is activated, (Conf / Cntr / SPFn. = 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.
g	After the end of a programm the stop function (OFF) must be selected before the programm can be started
	again.

5.6.3 Func - 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 / CoFF.= 5 and taking the Func - value into the extended operating level.

g Function Func is not suitable for timer activation.

Special change-over functions

20

KS 45

Operation

5.7Selecting the units

The unit to be displayed is determined via configuration DUnt. .

With selection “1 = temperature unit” , the displayed unit is determined by configuration Unit with the relevant conversions for Fahrenheit and Kelvin.

By selecting DUnt. = 22, display of any max. 5-digit unit or text can be determined.

4.5 1
		1	Unit (example): kilowatt hour
		2
kWh			Text (example): TAG no.
äüüü
1 2 M E	2
450.3
TI451
äüüü
1 2 M E

g For permanent display the value signals/other/D.Unt must be set in the mode "operating level" via the engineering tool.

21

KS 45

Functions

. 6 Functions

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 SLin. = 1: “Special linearization” are adjusted.

w w

w

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 V, 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.

Non-linear signals can be linearized using up to 16 segment points. Each segment point comprises an input ( In1. … In16.) and an output (Ou1. … Ou16.). 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 v alue for each input value is provided.

	With an In.x value switched to	OFF, all further segments are switched off.
+ Required: Condition for the input values is an ascending order.
	In1. < In2. < ...<	In16. .
g	For linearization of special thermocouples, the ambient temperature range should be defined exactly,
	becauseit is used to derive the internal temperature compensation.

See also page 60.

Linearization

22

KS 45

Functions

Ou..16
.
.
.
.
.
Ou1.
In1.	In16.

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.

mA / V

Example for mA/V

phys.
quantity
OuH.x
		phys. quantity
OuL.x
InL.x	InH.x	mA/V

g 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).

KS 45

23

Input scaling