West Control Solutions KS 92-1 User Manual
PMA Prozeß- und Maschinen-Automation GmbH
dli
90
Industrial and process controller
KS 90-1and KS 92-1
KS
-1
KS92-1
Operating manual
KS90-1
KS92-1
advance
ne
English
9499-040-62911
Valid from: 8499
û
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
© PMA Prozeß- und Maschinen-Automation GmbH • Printed in Germany
All rights reserved. No part of this document may bereproduced or published in any form
or by any means without prior written permission from the copyright owner.
A publication of PMA Prozeß- und Maschinen Automation
P.O.Box 310229
D-34058 Kassel
Germany
Contents
1 Mounting .............................. 5
2 Electrical connections ....................... 6
2.1 Connecting diagram ....................... 6
2.2 Terminal connection ........................ 7
3 Operation ............................. 11
3.1 Front view ............................ 11
3.2 Behaviour after power-on ..................... 12
3.3 Operating level .......................... 12
3.4 Error list / Maintenance manager ................. 13
3.5 Self-tuning ............................. 16
3.5.1 Preparation for self-tuning ...................16
3.5.2 Optimization after start-up or at the set-point .........17
3.5.3 Selecting the method ( ConF/ Cntr/ tunE).........17
3.5.4 Step attempt after start-up ..................18
3.5.5 Pulse attempt after start-up ...................18
3.5.6 Optimization at the set-point ..................18
3.5.7 Optimization at the set-point for 3-point stepping controller. . 20
3.5.8 Self-tuning start .........................21
3.5.9 Self-tuning cancellation.....................21
3.5.10 Acknowledgement procedures in case of
unsuccessful self-tuning ....................22
3.5.11 Examples for self-tuning attempts ...............23
3.6 Manual self-tuning......................... 24
3.7 Second PID parameter set .....................25
3.8 Alarm handling .......................... 26
3.9 Operating structure ........................ 28
4 Configuration level ........................29
4.1 Configuration survey ................... 29
4.2 Configuration parameters ................... 30
4.3 Set-point processing ........................ 44
4.3.1 Set-point gradient / ramp ....................44
4.4 Switching behaviuor ........................ 45
4.4.1 Standard ( CyCl= 0 ).....................45
KS 90-1 / KS 92-1 3
4.4.2 Switching attitude linear ( CyCl= 1 ).............45
4.4.3 Switching attitude non-linear ( CyCl= 2 ) ..........46
4.4.4 Heating and cooling with constant period ( CyCl= 3 )....47
4.5 Configuration examples ......................48
4.5.1 On-Off controller / Signaller (inverse) .............48
4.5.2 2-point controller (inverse) ...................49
4.5.3 3-point controller (relay & relay) ................50
4.5.4 3-point stepping controller (relay & relay) ...........51
4.5.5 Continuous controller (inverse).................52
4.5.6 D - Y - Off controller / 2-point controller with pre-contact . 53
4.5.7 Continuous controller with position controller ........54
4.5.8 Measured value output .....................55
5 Parameter setting level ...................... 56
5.1 Parameter survey ....................... 56
5.2 Parameters ............................. 57
5.3 Input scaling ............................ 60
5.3.1 Input Inp.1 and InP.3 ...........60
5.3.2 Input InP.2 ..........................60
6 Calibration level ......................... 61
7 Special functions ......................... 64
7.1 DAC®– motor actuator monitoring ...............64
7.2 O2measurement .......................... 66
7.2.1 Connection ...........................66
7.2.2 Configuration:..........................67
7.3 Linearization............................ 68
7.4 Loop alarm............................. 69
7.5 Heating current input / heating current alarm ...........69
7.6 KS9x-1 as Modbus master..................... 70
7.7 Back-up controller (PROFIBUS) ................. 70
8 BlueControl ............................ 71
9 Versions .............................. 72
10 Technical data .......................... 74
11 Safety hints ............................ 78
11.1 Resetting to factory setting, ....................80
4 KS 90-1 / KS 92-1
1 Mounting
min.48 (1.89")
92
Mounting
+0,8
10
(3.78")
96
48 (1.89")
max.
(0.4")
118
1199
1199
°C
°C
°F
°F
para
para
func
func
Ada
Ada
Err
Err
F
F
è
KS 92-1 advanced
KS 90-1
60°C
0°Cmin.
(4.65")
123
1234
1200
1200
SP.E
SP.2
SP.E
SP.2
advanced
4
max.
95% rel.
1..10
(0.04..0.4")
+0,6
45
+0.02
(1.77" )
Loc
locking switch
%
+0,8
+0.03
92
2
1
3
4
+0,8
92
(3.62" )
920.1
para
o
func
C
F
921.2
run
SP.E
SP.2
run
SP.E
SP.2
96
118
10
*
96
Ada
Err
KS 92-1 advanced
Ü
a
l
Fix the instrument only at top and bottom to avoid damaging it.
Safety switch:
For access to the safety switch, 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.
Loc open Access to the levels is as adjusted by means of BlueControl
â
(engineering tool) 2
closed 1 all levels accessible wihout restriction
1 Factory setting 2 Default setting: display of all levels
suppressed, password PASS = OFF
Caution! The unit contains ESD-sensitive components.
KS 90-1 / KS 92-1 5
Electrical connections
2 Electrical connections
2.1 Connecting diagram
3
1
2
90...250V
24VUC
OUT1
OUT2
OUT3
KS90-1. -4 ...
KS90-1. -5 ...
OUT4
KS90-1. -25...
!
V
V
d
b
c
e
8
9
0
RGND
DATA B
DATA A
RS485 RS422
Modbus RTU
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
a
+24V DC
OUT5
OUT6
24V GND
RXD-B
RXD-A
TXD-B
TXD-A
GND
di2
di3
U
1
2
3
di1
7
di2
4
5
6
7
g
HC
mA
INP2
f
5
8
9
10
11
(mV)
mA
0%
100%
INP3
KS90-1..-.1...
6
12
13
14
15
mA
Volt
INP1
4
(16)
Option
1
(2)
3
4
5
10
11
12
13
14
15
(16)
17
6
7
8
9
VP (5V)
DGND
RxD/TxD-N
RxD/TxD-P
Schirm/
Screen
T
17
(mV)
a
PROFIBUS-DP
Adapter
b
390 [
220 [
390 [
cd
DGND
9
8
7
VP (5V)
6
Profibus DP
e
max.
1200m
5
4
3
2
1
5
9
4
8
3
7
2
6
1
g
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
w
screw terminals for 0,5 to 2,5mm²
w
On instruments with screw terminals, the insulation must be stripped by min.
12 mm. Choose end crimps accordingly!
Connecting diagram 6 KS 90-1 / KS 92-1
2.2 Terminal connection
+
_
SSR
Power supply connection 1
See chapter "Technical data"
Electrical connections
Connection of outputs OUT1/2 2
2 OUT1/2 heating/cooling
Relay outputs (250V/2A), potential-free
changeover contact
L
Connection of outputs OUT3/4 3
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 input INP1 4
N
Input mostly used for variable x1 (process value)
a thermocouple
b resistance thermometer (Pt100/ Pt1000/ KTY/ ...)
c current (0/4...20mA)
d voltage (0/2...10V)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
(16)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
+
Connection of input INP2 5
f heating current input (0..50mA AC)
or input for ext. set-point (0/4...20mA)
g potentiometer input for position
feedback
Connection of input INP2 5
a Heating current input (0...50mA AC)
or input for ext. Set-point (0/4...20mA)
b Potentiometer input for position
feedback
Connection of input INP3 6
As input INP1, but without voltage
Connection of inputs di1, di2 7
Digital input, configurable as switch or
push-button
5 INP2 current tansformer
L
1
2
3
4
5
6
7
8
N
Logik
9
10
11
12
13
14
15
10
11
12
13
14
15
(16)
17
1
2
3
4
5
6
7
8
9
KS 90-1 / KS 92-1 7 Terminal connection
Electrical connections
Connection of inputs di2/3 8 (option)
Digital inputs (24VDC external), galvanically isolated, configurable as switch or
push-button
Connection of output U
9 (option)
T
Supply voltage connection for external energization
Connection of outputs OUT5/6 0 (option)
Digital outputs (opto-coupler), galvanic isolated, common positive control volta
ge, output rating: 18...32VDC
Connection of bus interface ! (option)
PROFIBUS DP or RS422/485 interface with Modbus RTU protocol
89 di2/3, 2-wire transmitter supply
OUT3
J
10
11
12
13
14
15
Option
14
(16)
17
13
15
-
+
-
g
+24VDC
3
0V
+
1
2
-
17,5V
22mA
K
5mA
5mA
+
-
1
(2)
3
4
5
6
7
8
9
10
11
12
13
14
15
(16)
17
J
Analog outputs OUT3 or OUT4 and transmitter supply UTare connected to
different voltage potentials. Therefore, take care not to make an external galvanic
connection between OUT3/4 and U
with analog outputs!
T
Terminal connection 8 KS 90-1 / KS 92-1
3 OUT3 transmitter supply
Electrical connections
3
13V
22mA
1
K
2
-
+
10
11
12
13
14
15
11
12
14
(16)
17
13
15
+
-
9 RS485 interface (with RS232-RS485 interface converter) *
R = 120...200 OhmT
RT
RGND connection optional
RGND
DATA B
DATA A
option
1
(2)
3
4
5
6
7
8
9
10
11
12
13
14
15
(16)
17
J
10
11
12
13
14
15
RGND
DATA B
DATA A
option
1
(2)
3
4
5
6
7
8
9
10
11
12
13
14
15
(16)
17
10
11
12
13
14
15
max. 1000m
"Twisted Pair” cable
RGND
DATA B
DATA A
R=100 Ohm
option
1
(2)
3
4
5
6
7
8
9
10
11
12
13
14
15
(16)
17
RT
R = 120...200 OhmT
10
11
12
13
14
15
PC
RS485-RS232
converter
* Interface description Modbus RTU in separate manual: see page 72.
KS 90-1 / KS 92-1 9 Terminal connection
Electrical connections
+
_
SSR
+
_
SSR
+
_
SSR
+
_
SSR
+
_
SSR
+
_
3 OUT3 as logic output with solid-state relay (series and parallel connection)
Parallel connection
Series connection
I =22mA
max
4V
I =22mA
max
12V
10
11
12
4V
12V
10
11
12
Logic
4V
KS9x-1 connecting example:
L1
L2
Fuse
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
KS90-1
Logik
10
11
12
13
14
(16)
1
2
3
4
5
6
7
8
9
SSR
15
17
Contactor
+
Fuse
Heating
1 TB 40-1 Temperaturelimiter
Standard-version (3 Relays):
TB40-100-0000D-000
further versions on requestr
1
2
3
4
1
TB 40-1
Temperaturelimiter
5
6
7
8
9
10
11
12
13
14
15
+
Resetkey
Fuse
N1
N2
a
CAUTION: Using a temperature limiter is recommendable in systems where
overtemperature implies a fire hazard or other risks.
Terminal connection 10 KS 90-1 / KS 92-1
3 Operation
1 2 3
4
F
SP.E
SP.2
920.1
921.2
C
para
func
Ada
Err
SP.E
SP.2
o
1200
1199
°C
°F
SP.2
SP.E
para
func
Ada
Err
F
1 2 3
4
123
4
1200
1199
°C
°F
para
func
123
4
123
4
SP.E
SP.2
C
para
func
Ada
Err
SP.E
SP.2
o
1200
1199
°C
°F
para
func
Ada
Err
123
4
1
2
3
4
5
6
$
7
8
%
&
(
123
4
SP.E
SP.2
C
para
func
Ada
Err
SP.E
SP.2
o
4
123
4
SP.E
SP.2
C
para
func
Ada
Err
SP.E
SP.2
o
123
4
SP.E
SP.2
C
para
func
Ada
Err
SP.E
SP.2
o
1200
1199
°C
°F
para
func
Ada
Err
123
4
123
4
SP.E
SP.2
C
para
func
Ada
Err
SP.E
SP.2
o
123
4
SP.E
SP.2
C
para
func
Ada
Err
SP.E
SP.2
o
1200
1199
°C
°F
para
func
Ada
Err
123
4
/
123
4
1200
1199
°C
°F
parap
123
4
123
4
C
para
func
o
1200
1199
°C
°F
para
func
Ada
Err
123
4
123
4
123
4
123
4
1199
123
4
4
9
123
4
para
o
4
0
123
4
C
para
func
o
4
§"
!
123
4
SP.E
SP.2
C
SP.E
SP.2
o
123
4
SP.E
SP.2
C
SP.E
SP.2
o
123
4
123
4
4
123
4
C
o
123
4
4
9
0
123
4
SP.2
C
SP.2
123
4
SP.E
SP.2
C
SP.E
SP.2
o
!
§"
123
4
C
para
func
o
1200
1199
°C
°F
123
4
123
4
C
para
func
o
1200
123
4
7
8
123
4
C
para
func
Ada
Err
o
$
%
&
/
(
123
4
C
para
func
o
123
4
para
o
123
4
5
6
1
2
3
123
4
1200
1199
°C
°F
123
4
3.1 Front view
Operation
1 Statuses of switching outputsOuT.1... 6 2 Process value display
3 Setpoint or correcting variable display 4 °C or °F display signalling
5 Signals ConF- and PArA level 6 Signals activated function key
7 Selft-tuning active 8 Entry into the error list
9 Bargraph or plain text display 0 Setpoint SP.2 is effective
! Setpoint SP.E is effective " Setpoint gradient is effective
§ Manual-automatic switchover: Off: automatic On: manual mode (adjustment possible)
Blinks: manual mode (adjustment not possible (r ConF/ Cntr/ MAn))
$ Enter key: call up extented operating level / error list
% Up/ down keys: changing setpoint or correcting variable
& automatic/manual or other functions ( r ConF /LOGI)
/ freely configurable function key with pure controller operation
( PC connection for BlueControl (engineering tool)
g
KS 90-1 / KS 92-1 11 Front view
LED colours: LED 1, 2, 3, 4: yellow, Bargraph: red, other LEDs: red
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.
Operation
A
M
l
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 the controller was in manual mode at supply voltage switch-off, the controller
will re-start with the last output value in manual mode at power-on.
3.3 Operating level
The content of the extended operating level is determined by means of BlueCon
trol (engineering tool). Parameters which are used frequently or the display of
which is important can be copied to the extended operating level.
time
out
utomatic
1199
1200
È
Ì
Ù
1199
Y21
i
Ò
Ò
i
anua
1199
Y21
È
Ì
Ù
1199
1200
time
out
-
È
Ù
only
display
Ù
Ì
Extended operating level
time
out
Error list (if error exists)
126
FbF.1
Err
Display
switching
126
2
Err
Behaviour after power-on 12 KS 90-1 / KS 92-1
3.4 Error list / Maintenance manager
Operation
With one or several errors, the extended operating le
vel always starts with the error list. Signalling an ac
tual entry in the error list (alarm, error) is done by the
Err LED in the display. To reach the error list press
Ù twice.
-
-
1199
°C
°F
para
func
Ada
Err
Err LED status Signification Proceed as follows
blinks
(status 2)
lit
(status 1)
Alarm due to
existing error
Error removed,
alarm not
Determine the error type in the error list
After error correction the unit changes to status 1
Acknowledge the alarm in the error list pressing key ÈorÌ
The alarm entry was deleted (status 0).
-
acknowledged
off
(status 0)
No error, all alarm
entries deleted
-Not visible except when acknowledging
-
Error list:
1200
SP.E
SP.2
Name
E.1
E.2
E.3
E.4
FbF.
1/2/3
Sht.
1/2/3
POL.
1/2/3
HCA
Description Cause Possible remedial action
Internal error,
cannot be
- E.g. defective EEPROM - Contact PMA service
- Return unit to our factory
removed
Internal error,
can be reset
Configuration
error,
- e.g. EMC trouble - Keep measurement and power supply
cables in separate runs
- Ensure that interference suppression
of contactors is provided
-
wrong configuration
-
missing configuration
-
Check interaction of configuration /
parameters
can be reset
Hardware error
Sensor break
INP1/2/3
Short circuit
INP1/2/3
INP1/2/3
-
Codenumber and hardware
are not identical
-
Sensor defective
-
Faulty cabling
-
Sensor defective
-
Faulty cabling
-
Faulty cabling
-
Contact PMA service
-
Elektronic-/Optioncard must be
exchanged
-
Replace INP1/2/3 sensor
-
Check INP1/2/3 connection
-
Replace INP1/2/3 sensor
-
Check INP1/2/3 connection
-
Reverse INP1/2/3 polarity
polarity error
Heating current
alarm (HCA)
-
Heating current circuit
interrupted, I< HC.A or
I> HC.A (dependent of
configuration)
-
Heater band defective
-
Check heating current circuit
-
If necessary, replace heater band
KS 90-1 / KS 92-1 13 Error list / Maintenance manager
Operation
Name
SSr
LooP
AdA.H
Description Cause Possible remedial action
Heating current
short circuit
(SSR)
Control loop
alarm (LOOP)
Self-tuning
heating alarm
Current flow in heating
circuit with controller off
SSR defective
Input signal defective or not
connected correctly
Output not connected
correctly
See Self-tuning heating
error status
Check heating current circuit
If necessary, replace solid-state relay
-
Check heating or cooling circuit
Check sensor and replace it, if
necessary
Check controller and switching
device
see Self-tuning heating error status
-
(ADAH)
AdA.C
Self-tuning
heating alarm
See Self-tuning cooling
error status
see Self-tuning cooling error status
-
cooling (ADAC)
dAC DAC-Alarm Actor error see errorstatus DAC-function
LiM.1/
2/3
Inf.1
Inf.2
stored limit
alarm 1/2/3
time limit value
message
duty cycle
message
adjusted limit value 1/2/3
exceeded
adjusted number of
operating hours reached
- adjusted number of duty
cycles reached
check process
-
application-specific
-
- application-specific
(digital ouputs)
E.5 Internal error in
DP module
dp.1 No access by bus
master
dp.2 Faulty
configuration
dp.3 Inadmissible
parameter
self-test errorinternal
communication interrupted
bus errorconnector
problemno bus connection
Faulty DP configuration
telegram
Faulty DP parameter
setting telegram
Switch on the instrument
againContact PMA service
Check cableCheck connectorCheck
connections
Check DP configuration telegram in
master
Check DP parameter setting
telegram in master
setting telegram
sent
dp.4 No data
communication
Bus errorAddress
errorMaster stopped
Check cable connectionCheck
addressCheck master setting
g
Saved alarms (Err-LED is lit) can be acknowledged and deleted with the digital
input di1/2/3, the è-key or the Ò-key.
Configuration, see page 37: ConF / LOGI / Err.r
g
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.
Error list / Maintenance manager 14 KS 90-1 / KS 92-1
Self-tuning heating ( ADA.H) and cooling ( ADA.C) error status:
Operation
Error
status
0
3
4
5
6
7
8
Description Behaviour
No error
Faulty control
Re-configure controller (inverse i direct)
action
No response of
process variable
The control loop is perhaps not closed: check sensor,
connections and process
Low reversal point Increase ( ADA.H) max. output limiting Y.Hi or decrease (
ADA.C) min. output limiting Y.Lo
Danger of exceeded
If necessary, increase (inverse) or reduce (direct) set-point
set-point (parameter
determined)
Output step change
too small (dy > 5%)
Set-point reserve too
small
Increase ( ADA.H) max. output limiting Y.Hi or reduce (
ADA.C) min. output limiting Y.Lo
Acknowledgment of this error message leads to switch-over to
automatic mode.If self-tuning shall be continued,
increase set-point (invers), reduce set-point (direct)
or decrease set-point range
(r PArA / SEtp / SP.LO and SP.Hi )
DAC function ( DAC) error status:
Error status
0
3
4
5
6
No error
Output is blocked Check the drive for blockage
Wrong method of operation Wrong phasing, defect motor capacitor
Fail at Yp measurement Check the connection to the Yp input
Calibration error Manual calibration necessary
Description Behaviour
KS 90-1 / KS 92-1 15 Error list / Maintenance manager
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
®
.
-
Parameter set 2: analogous to parameter set 1 (see page 25)
3.5.1 Preparation for self-tuning
Adjust the controller measuring range as control range limits. Set values
w
rnG.L and rnG.H to the limits of subsequent control.
(ConfigurationrControllerrlower and upper control range limits)
ConFrCntrr rnG.L and rnG.H
Determine which parameter set shall be optimized.
w
-The instantaneously effective parameter set is optimized.
r Activate the relevant parameter set (1 or 2).
Determine which parameter set shall be optimized (see tables above).
w
Select the self-tuning method
w
see chapter 3.5.3
-Step attempt after start-up
-Pulse attempt after start-up
-Optimization at the set-point
Self-tuning 16 KS 90-1 / KS 92-1
3.5.2 Optimization after start-up or at the set-point
The two methods are optimization after start-up and at the set-point.
As control parameters are always optimal only for a limited process range, vari
ous methods can be selected dependent of requirements. If the process behaviour
is very different after start-up and directly at the set-point, parameter sets 1 and 2
can be optimized using different methods. Switch-over between parameter sets
dependent of process status is possible (see page ).
Optimization after start-up: (see page 4)
Optimization after start-up requires a certain separation between process value
and set-point. This separation enables the controller to determine the control pa
rameters by evaluation of the process when lining out to the set-point.
This method optimizes the control loop from the start conditions to the set-point,
whereby a wide control range is covered.
We recommend selecting optimization method “Step attempt after start-up”
with tunE = 0 first. Unless this attempt is completed successfully, we recom
mend a “Pulse attempt after start-up”.
Operation
-
-
-
Optimization at the set-point: (see page 18)
For optimizing at the set-point, the controller outputs a disturbance variable to the
process. This is done by changing the output variable shortly. The process value
changed by this pulse is evaluated. The detected process parameters are converted into control parameters and saved in the controller.
This procedure optimizes the control loop directly at the set-point. The advantage
is in the small control deviation during optimization.
3.5.3 Selecting the method ( ConF/ Cntr/ tunE)
Selection criteria for the optimization method:
Step attempt after start-up Pulse attempt after
start-up
tunE =0
tunE =1
tunE =2
sufficient set-point reserve
is provided
sufficient set-point
reserve is provided
always step attempt after
start-up
Optimization at the
set-point
sufficient set-point reserve is
not provided
sufficient set-point reserve is
not provided
Sufficient set-point reserve:
inverse controller:(with process value < set-point- (10% of rnGH - rnGL)
direct controller: (with process value > set-point + (10% of rnGH - rnGL)
KS 90-1 / KS 92-1 17 Self-tuning
Operation
3.5.4 Step attempt after start-up
Condition: - tunE = 0 and sufficient set-point reserve provided
or - tunE =2
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 pro
cess 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 parame
ters.
-
-
3.5.5 Pulse attempt after start-up
Condition: - tunE = 1 and sufficient set-point reserve provided.
The controller outputs 0% correcting variable or Y.Lo and waits, until the process
is at rest (see start conditions page 8)
Subsequently, a short pulse of 100% is output (Y=100%) and reset.
The controller attempts to determine the optimum control parameters from the
process response. If this is completed successfully, these 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 and line-out to the set-point, correcting
variable "heating" remains unchanged and a cooling pulse (100% cooling energy)
is output additionally. After successful determination of the “cooling parame
ters”, the optimized parameters are used for line-out to the set-point.
3.5.6 Optimization at the set-point
Conditions:
A sufficient set-point reserve is not provided at self-tuning start (see page 17).
w
-
tunE is0or1
w
With Strt = 1 configured and detection of a process value oscillation by
w
more than ± 0,5% of (rnG.H - rnG.L) by the controller, the control
parameters are preset for process stabilization and the controller realizes an
optimization at the set-point (see figure “Optimization at the set-point”).
when the step attempt after power-on has failed
w
with active gradient function ( PArA/ SETP/ r.SP¹ OFF), the set-point
w
gradient is started from the process value and there isn't a sufficient set-point
reserve.
Self-tuning 18 KS 90-1 / KS 92-1
Operation
Optimization-at-the-set-point procedure:
The controller uses its instantaneous parameters for control to the set-point. In li
ned out condition, the controller makes a pulse attempt. This pulse reduces the
correcting variable by max. 20% 1, to generate a slight process value unders
hoot. The changing process is analyzed and the parameters thus calculated are re
corded in the controller. The optimized parameters are used for line-out to
theset-point.
Optimization at the set-point
-
set-point
process value
-
-
correcting
variable
With a 3-point controller, optimization for the “heating“ or “cooling” parameters
occurs dependent of the instantaneous condition.
These two optimizations must be started separately.
1 If the correcting variable is too low for reduction in lined out condition it is
increased by max. 20%.
KS 90-1 / KS 92-1 19 Self-tuning
Operation
3.5.7 Optimization at the set-point for 3-point stepping controller
With 3-point stepping controllers, the pulse attempt can be made with or without
position feedback. Unless feedback is provided, the controller calculates the mo
tor actuator position internally by varying an integrator with the adjusted actuator
travel time. For this reason, precise entry of the actuator travel time (tt), as time
between stops is highly important. Due to position simulation, the controller
knows whether an increased or reduced pulse must be output. After supply volta
ge switch-on, position simulation is at 50%. When the motor actuator was varied
by the adjusted travel time in one go, internal calculation occurs, i.e. the position
corresponds to the simulation:
Simulation actual position
-
-
Internal calculation
tt
Internal calculation always occurs, when the actuator was varied by travel time
tt in one go
, independent of manual or automatic mode. When interrupting the
variation, internal calculation is cancelled. Unless internal calculation occurred
already after self-tuning start, it will occur automatically by closing the actuator
once.
Unless the positioning limits were reached within 10 hours, a significant deviati
on between simulation and actual position may have occurred. In this case, the
controller would realize minor internal calculation, i.e. the actuator would be clo
sed by 20 %, and re-opened by 20 % subsequently. As a result, the controller
knows that there is a 20% reserve for the attempt.
Self-tuning 20 KS 90-1 / KS 92-1
-
3.5.8 Self-tuning start
Start condition:
For process evaluation, a stable condition is required. Therefore, the
w
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
oscillation is smaller than ± 0,5% of (rnG.H - rnG.L).
For self-tuning start after start-up, a 10% difference from (SP.LO ... SP.Hi)
w
is required.
Operation
g
3.5.9 Self-tuning cancellation
Self-tuning start can be blocked via BlueControl®(engineering tool) ( P.Loc).
Strt = 0 Only manual start by pressing keys Ù and È
simultaneously or via interface is possible.
Strt = 1 Manual start by press keys Ù and È simultaneously
via interface and automatic start after power-on and detection
of process oscillations.
Ada LED status Signification
blinks Waiting, until process calms down
lit Self-tuning is running
off Self-tuning not activ or ended
By the operator:
Self-tuning can always be cancelled by the operator. For this, press Ù and È
key simultaneously.With controller switch-over to manual mode after self-tuning
start, self-tuning is cancelled. When self-tuning is cancelled, the controller will
continue operating using the old parameter values.
1199
°C
°F
1200
para
func
Ada
Err
SP.E
SP.2
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. The controller continues operating with the old parameters in
automatic mode. In manual mode it continues with the old controller output va
lue.
KS 90-1 / KS 92-1 21 Self-tuning
-
Operation
3.5.10 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 15: "Error status self-tuning heating ( ADA.H) and cooling ( ADA.C)"
Self-tuning 22 KS 90-1 / KS 92-1
3.5.11 Examples for self-tuning attempts
S
(controller inverse, heating or heating/cooling)
Operation
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 at
tempt 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.
Self-tuning at the set-point a
The process is controlled to the
set-point. With the control deviation
constant during a defined time (1)
(i.e. constant separation of process value
and set-point), the controller outputs a
reduced correcting variable pulse (max.
20%) (2). After determination of the
control parameters using the process
characteristic (3), control is started
using the new parameters (4).
100%
100%
X
W
100%
0%
tart r
X
W
Y
0%
Star t r
X
W
Y
0%
start r
Y
1
blinks
1
blinks
r
blinks
2
1
t
3
2
2
3
4
t
t reversal point
t
t reversal point
t
Three-point controller a
The parameter for heating and cooling are
X
W
3
rt
determined in two attempts. The heating
power is switched on (1). Heating para
meters Pb1, ti1, td1 and t1 are de
termined at the reversal point. Control to
the set-point occurs(2). With constant
control deviation, the controller provides a
cooling correcting variable pulse (3). Af
-
-
+100%
Y0%
-100%
Start r
1
t reversal
point
2
4
t
5
-
ter determining its cooling parameters
Pb2, ti2, td2 and t2 (4) from the
process characteristics , control operation is started using the new parameters (5).
a
KS 90-1 / KS 92-1 23 Self-tuning
During phase 3, heating and cooling are done simultaneously!
Operation
y
3.6 Manual self-tuning
The optimization aid can 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
and x
g
(step change from 0 to 100 %) or Dt and Dx (partial step re
max
.
max
100%
Y
h
0%
x
t
Tg
X
max
-
-
{X
{t
Tu
y = correcting variable
Y
h
Tu = delay time (s)
Tg = recovery time (s)
X
max
V
max
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.
= control range
= maximum process value
Xmax
=
, maximum rate of increase v
u
Tg
{{x
=
= max. rate of increase of process value
t
, control range Xhand characteristic K ac
max
t
-
-
Manual self-tuning 24 KS 90-1 / KS 92-1
Operation
Parameter adjustment effects
Parameter Control Line-out of
disturbances
Pb1 higher increased damping slower line-out slower reduction of duty cycle
lower reduced damping faster line-out faster reduction of duty cycle
td1 higher reduced damping faster response to
disturbances
lower increased damping slower response to
disturbances
ti1 higher increased damping slower line-out slower reduction of duty cycle
lower reduced damping faster line-out faster reduction of duty cycle
Start-up behaviour
faster reduction of duty cycle
slower reduction of duty cycle
Formulas
K = Vmax *
Tu
With 2-point and 3-point
controllers, the cycle time
must be adjusted to
t1 / t2 £ 0,25 * Tu
controller behavior Pb1 [phy. units] td1 [s] ti1 [s]
PID 1,7*K 2*Tu 2*Tu
PD 0,5 * K Tu OFF
PI 2,6 * K OFF 6*Tu
PKOFF OFF
3-point-stepping 1,7 * K Tu 2 * Tu
3.7 Second PID parameter set
The process characteristic is frequently affected by various factors such as process value, correcting variable and material differences.
To comply with these requirements, KS 9x-1 can be switched over between two
parameter sets.
Parameter sets PArA and PAr.2 are provided for heating and cooling.
Dependent of configuration ( ConF/LOG/Pid.2), switch-over to the second pa
rameter set ( ConF/LOG/Pid.2) is via one of digital inputs di1, di2, di3,
key è or interface (OPTION).
g
Self-tuning is always done using the active parameter set, i.e. the second
parameter set must be active for optimizing.
-
KS 90-1 / KS 92-1 25 Second PID parameter set
Operation
3.8 Alarm handling
Max. three alarms can be configured and assigned to the individual outputs. Ge
nerally, outputs OuT.1... OuT.6 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 and delay dEl.x of each limit value is adjustable.
Ü Operaing principle absolut alarm
L.1 = OFF
InL.1
H.1
HYS.1
LED
InH.1
* Operating principle relative alarm
L.1 = OFF
SP
InL.1
H.1
HYS.1
-
-
InH.1
LED
H.1 = OFF
InL.1
InL.1
H.1
L.1
LED
L.1
HYS.1
LED
HYS.1 HYS.1
InH.1
InH.1
LED
H.1 = OFF
InL.1
InL.1
2
LED
LED
HYS.1
HYS.1
L.1
SP
InH.1
L.1
SP
InH.1
H.1
HYS.1
LED
2
1: normally closed ( ConF/ Out.x/O.Act=1 ) (see examples in the drawing)
2: normally open ( ConF/ Out.x/O.Act= 0 )(inverted output relay action)
Alarm handling 26 KS 90-1 / KS 92-1
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