West Control Solutions KS 800 Operating Instructions
©PMA Prozeß- und Maschinen-Automation GmbH 2004. 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
by the copyright owner.
A publication of PMA Prozeß- und Maschinen-Automation GmbH
Subject to change without notice.
PMA Prozeß- und Maschinen-Automation GmbH
P.O. Box 31 02 29
D 34058 Kassel
Germany
Restriction of warranty:
No warranty is given for the complete correctness of this manual, since errors can never avoided
completely despite utmost care. Any hints are welcome and gratefully accepted.
Multi-Temperature-Controller KS 800
Contents
1 Safety hints ....................................................... 5
1.1 Electromagnetic compatibility ...................................... 5
2 General .......................................................... 6
2.1 Versions ..................................................... 6
2.1.1 Possible output configurations ................................ 7
3 Installation ........................................................ 7
3.1 Mounting .................................................... 7
3.2 Dismounting .................................................. 8
4 Electrical connection ................................................ 9
4.1 Terminals .................................................... 9
4.2 Bus-Stecker ................................................. 10
4.3 Galvanic isolations ............................................ 11
4.4 Supply voltage ............................................... 12
4.5 Fuses ...................................................... 12
5 Inputs ........................................................... 13
5.1 Analog inputs ................................................ 13
5.1.1 Thermocouple inputs ..................................... 13
5.1.2 Cold-junction temperature compensation ....................... 14
5.2 DC voltage .................................................. 14
5.3 Resistance thermometer ........................................ 14
5.4 Screening ................................................... 15
5.5 Heating current measurement and heating current alarm ................. 15
5.6 Input circuit examples .......................................... 16
5.7 Digital inputs ................................................. 17
5.8 Input/output forcing ............................................ 17
6 Outputs ......................................................... 18
6.1 Controller outputs: ............................................. 18
6.2 Controller outputs, continuous .................................... 19
6.2.1 Analog output allocation...................................... 20
6.3 Alarm outputs ................................................ 20
6.4 Constant voltage and auxiliary relays ............................... 20
7 Circuit diagrams ................................................... 21
7.1 Input/output circuit diagram ...................................... 21
7.2 KS 800 overall connecting diagram with/without continious outputs .......... 22
7.3 KS 800 overall connecting diagram with constant voltage 10V ............. 23
8 Digital interfaces .................................................. 24
8.1 Engineering tool interface ....................................... 24
8.2 BUS interfaces ............................................... 24
8.2.1 BUS-Connector ......................................... 24
8.2.2 DeviceNet adaptor ....................................... 25
8.38.2.3 COM2 interface ......................................... 26
8.2.4 Terminating resistors ..................................... 27
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Multi-Temperature-Controller KS 800
9 Indicator LEDs .................................................... 27
9.1 Outputs ..................................................... 27
9.2 PWR, COM and alarm indicator LED ............................... 27
10 Maintenance and measures in case of trouble ............................ 28
10.1 Cleaning .................................................... 28
10.2 Trouble shooting .............................................. 28
10.3 Shut-down .................................................. 28
10.4 Customer Support Hotline ....................................... 28
UL-Zulassung .......................................................33
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Multi-Temperature-Controller KS 800
1 Safety hints
Following the enclosed safety hints 9499 047 07101 is indispensable!
For hints on the power supply to be used, see section 4.3 Supply voltage
1.1 Electromagnetic compatibility
The unit conforms to European guideline 89/336/EEC and is provided with the CE marking. The
following European generic standards are met: Electromagnetic radiation: EN 50081-1 and elec-
tromagnetic immunity: EN 50082-2
For compliance with EN 50082-2, the analog input leads must be screened.
The unit is suitable for use in industrial areas (there may be radio interference in residential areas).
Electromagnetic radiation can be reduced considerably, if the instrument is installed in a grounded
metal control cabinet.
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Multi-Temperature-Controller KS 800
2 General
KS 800 is a microcomputer-based multi-loop temperature controller. Functions "set-point lowering"
and "heating/cooling with four alarms" make it ideally suited for temperature control of plastics 20
processing machinery, moulds, packaging machinery, tempering units and similar thermal processes. Furthermore, with high-power heating elements (e.g. in hot runner moulds), the selectable
functions "start-up circuit" and "output hold" in case of sensor break ensure increased element life
and prevent interruptions during production. The self-tuning feature guarantees very short start-up
times.
2.1 Versions
These operating notes are valid for the three versions, which are only different in the communication interface:
Multiple temperature controller with RS485 / RS422 interface and ISO 1745 protocol.
9407 480 00001 KS 800-RS: Without analog outputs
9407 480 00101 KS 800-RS: With analog outputs, standard current signal 0/4...20mA
9407 480 00201 KS 800-RS: With analog outputs, standard voltage signal 0...10V
9407 480 00301 KS 800-RS: With 10V= constant-voltage
Multiple temperature controller with Profibus DP interface and Profibus DP protocol.
9407 480 30001 KS 800-DP: Without analog outputs
9407 480 30101 KS 800-DP: With analog outputs, standard current signal 0/4...20mA
9407 480 30201 KS 800-DP: With analog outputs, standard voltage signal 0...10V
9407 480 30301 KS 800-DP: With 10V= constant-voltage
Multiple temperature controller with CANbus interface and CANopen protocol.
9407 480 60001 KS 800-CAN: Without analog outputs
9407 480 60101 KS 800-CAN: With analog outputs, standard current signal 0/4...20mA
9407 480 60201 KS 800-CAN: With analog outputs, standard voltage signal 0...10V
9407 480 60301 KS 800-CAN: With 10V= constant-voltage
Multiple temperature controller with CANbus interface and Device-Net protocol.
9407 480 70001 KS 800-DN: Without analog outputs
9407 480 70101 KS 800-DN: With analog outputs, standard current signal 0/4...20mA
9407 480 70201 KS 800-DN: With analog outputs, standard voltage signal 0...10V
9407 480 70301 KS 800-DN: With 10V= constant-voltage
The differences between the KS 800 versions are only in the field bus / serial interface.
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Multi-Temperature-Controller KS 800
2.1.1 Possible output configurations
Provided that other criteria are taken into account, the following controller configurations are
possible:
Signaller with one output
Signaller with two outputs
Two-point controller (heating switching)
Three-point controller (heating switching, cooling switching)
Three-point controller (heating continuous, cooling switching)
Three-point controller (heating switching, cooling continuous)
Three-point stepping controller (without position feedback)
Continuous controller
Split-range controller (heating and cooling continuous, 0...100% each; max. 4 controllers)
Three-point controller with watercooling (water vaporization)
Limitter with latch function
When configuring a controller output as a continuous output, the relevant switching output is firmly
assigned to 0% duty cycle.
With unused analog outputs, the output variable is 0V or 0mA.
3 Installation
3.1 Mounting
KS 800 is provided for fast clip-on mounting to "top hat" standard rails 35 x 7,5 to EN 50 022,
EN 50 035 and EN 50 045.
KS 800 earthing is via a spring to the "top hat" rail. Therefore, this rail must have a good, conducting connection with the grounded mounting wall (layer of lacquer, non-conducting mounting wall,
Eloxal, ...). If necessary, the "top hat" rail must be earthed using a separate connection.
Single unit: For mounting, pull the two latches on the sides upwards by approx. 5 mm via a click
point and snap on the unit to the mounting rail. Press these latches down to lock the unit in position
on the rail.
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Multi-Temperature-Controller KS 800
Several units: For mounting several units side by side, snap on the first unit to the rail and lock
only the side on which no
approx. 2 cm beside the first unit and shift it sideways to connect it to the first unit (locking pins
click into position). Press down the second latch of the first unit only now.
The connectors on the instrumentside (board-toboard connector; type: AMP champ-050-connection)
are used only
units mounted side by side.
for CANBUS through-connection, i.e. one CANbus connection is sufficient for several
other unit shall be mounted. Snap on the second unit like the first one,
Bus connectors: These connectors are not
this case, each unit must be connected to the bus separately via the 9-pin sub-D-connectors.
If the KS 800 units are operated together with other P-Open components in a CANbus system, the
KS 800 units must be connected as last
by side on a rail. Otherwise, the individual component cannot be addressed. (The "addressing line"
is interrupted by KS 800.)
3.2 Dismounting
For dismounting, the leads need not be disconnected.
Before removing, mark the upper parts of the connectors and the corresponding lower parts, because the terminals are protected by design against distortion but not against wrong polarity.
For releasing the upper part of a terminal, press the two red ejectors in a terminal row towards the
circuit board by means of a screwdriver, if necessary.
For releasing the unit from the mounting rail, draw the two side latches (1) forwards by approx.
5mm (latch released) and remove the unit from the mounting rail by tipping it down or up.
For replacing an "inner" one of several units mounted side by side, start releasing the latch (and the
latch of the following unit!) at the end of the row and shift the unit sideways. Repeat this procedure
until reaching the unit which must be replaced. When its locking pins are free on both sides, the unit
can be tipped down or up out of the mounting rail.
used with the KS 800 Profibus and RS485 versions. In
instruments at the left or the right end of the modules side
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Multi-Temperature-Controller KS 800
4 Electrical connection
• Measurement and signal leads may carry max. 50 V rms against earth.
• Mains cables must be kept separate from signal and measurement cables.
• For protection of the outputs and avoiding interference, connected final elements must be
fitted with protective circuits according to manufacturer specification.
4.1 Terminals
All terminals leading to the process are designed as (plug-in) screw terminals or spring clamps.
The terminals are not included in the scope of delivery and must be ordered separately.
Type: PHOENIX COMBICON
Two types are available:
Screw terminal 4 x FRONT-MSTB 2,5/18-ST-5,08 1 x FRONTMSTB 2,5/8-ST-5,08
PMA Order-No. 9407 799 00001 9407 799 00011
Spring clamp 4 x FK-MSTBP 1,5/18-ST-5,08 8-pole not suitable
PMA Order-No. ----- ----For units with analog outputs,
2 x 8-pole terminal, order no. 231-308/026-000, resp. 9407 799 00011
is required additionally.
Note: The screwless spring clamps are shown in the KS 800 figures. These clamps have a sepa-
rate test socket. With the screw terminals, the screw heads are used for test measurements.
Connecting capacity
FRONT-MTSB 2,5/...-ST FK-MSTBP 1,5/...-ST
rigid flexible1) rigid flexible1)
One wire [mm²] 0,2 - 2,5 0,25 - 2,5 0,2 - 1,5 0,25 - 1,5
Multiple-wire connection [mm²]2) 0,2 - 1,5 0,25 - 1,0 0,2 - 1,0 0,5 - 0,753)
1
) with end crimps
2
) 2 wires of equal cross section
3
) with TWIN end crimps
Type : WAGO Multi-Connection-System MIDI
Spring-clamp 4 x female connector with CAGE CLAMP order no. 231-318/026-000
PMA Order-No. 9463 000 05341
1 x female connector with CAGE CLAMP order no. 231-308/026-000
PMA Order-No. 9463 000 05321
Connecting capacity
Only one wire: 0,08 - 2,5 mm², single-wire, multiple-wire, fine-wire, end crimp, pin cable shoe
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Multi-Temperature-Controller KS 800
For units with analog outputs,
2 x 8-pole terminal, order no. 231-308/026-000, resp. 9463 000 05321 is required additionally.
4.2 Bus-Stecker
For connecting KS 800 to the fieldbus system, the connectors listed in the table must be used:
Profibus Canbus; RS422/485 DeviceNet
z.B. Siemens*)
6ES7 972-0BA10-0XA0
6ES7 972-0BA10-0BB0
Sub-D-connector/socket; prefer commercially available metal/metalized
versions
Special adaptor
PMA order no.
9407 799 00301
6ES7 972-0BA10-0BA0
6GK1 500-0EA00
*
)These connectors are not available from PMA.
Specification of the order number is not binding, as these numbers can always be changed by
Siemens.
Note! For pin allocation see chapters 8.2.1 und 8.2.2
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Multi-Temperature-Controller KS 800
4.3 Galvanic isolations
The galvanic isolations of KS 800 are shown in the following diagram.
Identical block shading means that blocks are galvanically connected.
I.e. all outputs are galvanically connected, but isolated from inputs and microcontroller (controller).
All inputs are also galvanically connected.
An exception are the digital inputs/outputs, which are connected with controller outputs (and supply
voltage) independent of their configuration.
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