West Control Solutions KS 94 User Manual
Industrial controller KS 94
Operating Instruction
9499 040 44211
S94
Gültig ab: 8363
Inhalt
1. Front view ..............5
2. Safety notes .............5
3. Electromagnetic compatibility . . . 5
4. Technical data r data sheet,
order no. 9498 737 28233 ......5
5. Maintenance / Behaviour in case
of trouble ...............6
6. Further information.........6
7. Mounting ...............6
8. Electrical connections ........7
8.1 Notes . . . . . . . . . . . . . . . . . 7
8.2 Connecting input INP1 . . . . . . . . 7
8.3 Connecting input INP6 . . . . . . . 8
8.4 Connecting input INP5 . . . . . . . 8
8.5 Connecting the power supply . . . . 8
8.6 Connecting the outputs OUT2/4/5 . . 8
8.7 Connecting output OUT1 . . . . . . 8
8.8 Digital inputs and outputs (di / do) . 8
8.9 Connecting the bus interface . . . . 9
8.10 Connecting the inputs INP3 / INP4 . 9
8.11 Connecting the output OUT3 . . . . 9
8.12 Versions with integr. supply voltage 10
9. Operation (survey) .........11
9.1 The menues 1...3 . . . . . . . . . . 11
9.2 The operating level . . . . . . . . . 11
9.3 Operating the programmer: . . . . . 12
9.4 Calibration: ............12
9.5 DAC – motor actuator monitoring . .
(Digital Actor Control DAC®) . . . . .13
9.6 Self-tuning (automatic optimization of
control parameters) . . . . . . . . .13
9.7 Parameter and configuration level . 14
10. Configuration............15
10.1 General . . . ............15
10.2 Basic structure. . . . . . . .....15
10.3 Main groups . . . . . . . . .....18
10.4 CONTR: Controller . . . . . . . . . 19
10.5 SOURCE: Input signal allocation . . 21
10.6 INPUT: inputs . . . . . . . .....23
10.7 OUTPT: outputs. . . . . . . . . . . 27
10.8 ALARM: alarms ..........31
10.9 TUNE:self-tuning ..........32
10.10 DISP: User interface for operation . 32
10.11 AUX: Additional functions . . . . . 33
10.12 Examples of configuration . . . . . 35
11. Parameters .............36
11.1 General . . . ............36
11.2 Set-point function ..........38
11.3 Time function . . . . . . . .....38
11.4 Programmer functions . . . . . . . 38
11.5 Alarm function . . . . . . . . . . . 39
11.6 Self-tuning. . . . . . . . . . . . . . 39
11.7 Control algorithm ..........40
11.8 Input processing . . . . . . . . . . . 41
11.9 Miscellaneous . . . . . . . .....42
11.10 Signals . . . . . . . . . . . . . . . . 42
12. Versions ...............43
13. ....................43
13.1 Input and output allocation with . . .
pre-configured units. . . . . . . . .....44
Symbol definition:
a
K
J
DAC
General warning (caution, following the warnings in the instruction)
Protective earth
Earth connection
®
is a patented method and a registered trademark of Regeltechnik Kornwestheim GmbH.
All rights reserved. No part of this documentation may be reproduced or published in any form
or by any means without prior written permission from the copyright owner
A publication of PMA Proze- und Maschinen-Automation. Subject to alterations without notice.
PMA Prozess- und Maschinen-Automation GmbH 2000, Printed in Germany (2003).
PMA Prozess- und Maschinen-Automation GmbH • P.O.Box 310 229 • D-34058 Kassel - Germany
1. Front view
English
LED 2 e.g. Cooling LED 3 e.g. Alarm 1
LED 1 e.g. Heating LED 4 e.g. Alarm 2
Text 1 e.g. physical unit Display 2 e.g. Set-point
Text 2 e.g. Bargraph / Dialogue
Manual/Automatic key Decrement key (u)
Locking screw: Locks the controller module in the housing.
w
Front view
Locking screw
Display 1 e.g. Process value
Selection key
PC interface Increment key (z)
LEDs: indicates the statuses of controller outputs Y1, Y2 and alarms LIM1, LIM2 (other settings at
w
configuration level C.800 r page 30).
Display 1: indicatess process value at operating and parameter level, or the configuration code at
w
configuration level.
Display 2: indicates the set-point (automatic mode) or the correcting value (manual mode) in operating
w
level. The values are adjustable directly with ID. Further displays at operating level r page 9. In
parameter and configuration level, values and codes described with text1 are indicated (r page 12).
w
Text 1: indicates the short-form dialogue or the unit of display 2.
w
Text 2: indicates the output bargraph (other selections possible in configuration level C.800).
Keys HDIM: For the certain function r pages 9 and 12.
w
PC interface: PC connection for configuration/parameter setting/operation with an engineering tool.
2. Safety notes
Following the enclosed safety instructions 9499 047 07101 is indispensable!
The insulation of the instrument conforms to EN 61 010-1 with pollution degree 2, overvoltage
category III, operating voltage 300 V and protection class I. Additional with horizontal installation, a
protection to prevent live part, e.g. wire ends, from dropping into the open housing of a withdrawn
controller must be fitted.
3. Electromagnetic compatibility
The instrument conforms to European Directive 89/336/EEC and will be provideed with the
CE-marking. The following European Generic Standards are met: Emission: EN 50081-2 and
Immunity: EN 50082-2. The unit is suitable for use in industrial areas (in residential areas, RF
interference may occur). The electromagnetic radiation can be reduced decisively by installing the
unit in a grounded metal switch cabinet.
4. Technical data r data sheet, order no. 9498 737 28233
5 Operating instruction KS94
Maintenance / Behaviour in case of trouble
96
96
96 96
92
+0,8
92 ?24
+0,8
1...16
160
2
1
8.8.8.8
8.8.8.8
min. 0°C
50°Cmax.
max.
95% rel.
W2:ÀC
Y:ыыыыыо 55%
5. Maintenance / Behaviour in case of trouble
The controller needs no maintenance. The rules to be followed in case of trouble are:
Check mains (voltage, frequency and correct connections),wcheck, if all connections are correct,
w
check the correct funktion of the sensors and final elements,wcheck the configuration words for
w
required functions andwcheck the adjusted parameters for required operation. If the controller still
does not work properly after these checks, shut down the controller and replace it.
Cleaning:Housing and Front can be cleaned by means of a dry, lint-free cloth. No use of solvents or
cleansing agents!
6. Further information
A manual with the order no. 9499 040 44811 gives further information to the chapters of this
operating notes.
7. Mounting
S.I.L. switch: with the switch closed, transition to
parameter and configuration level is disabled.
When making an attempt to change over to the
parameter level, ”ParaL” is displayed (text1).
Correcting variable, set-point and parameters at
the ”extended operating level” remain available
for selecting and changing. For access to the S.I.L.
switch, release the locking screw and withdraw the
instrument module from the housing. Subsequently,
re-insert the controller module into the housing and
mount it with screws.
Protection mode IP65: 4 fixing clamps must be
used. The instruments insert must be placed strongly
an locked strongly by means of the locking screw.
l
Operating instruction KS94 6
Caution! The instrument contains ESD-hazarded
components.
8. Electrical connections
Electrical connections
galvanic isolation
* Versions with integrated supply voltage (connection example look at page 10)
8.1 Notes
q
q
q
The ground connection of earth terminal A11 (terminal P13 with continuous controllers, too) should
be kept separate from the mains and as short as possible (15 cm during test). Keep mains cables
separate from signal and measurement input leads. We recommend twisted and screened
measurement input leads (screen contacted to measurement earth).
When connecting a contactor to a relay output, an RC protective circuit is necessary, to avoid voltage
peaks which can cause trouble to the controller.
Individual or common fuse protection must be fitted (1 A per instrument).
8.2 Connecting input INP1 1
Input for main process value x1 (actual value).
Thermocouple
x1
a
d
Potentiometric transducer
b
e
Resistance thermometer
(Pt 100)
Current (0/4...20mA)
7 Operating instruction KS94
Temperature difference (}1-}2)
c
(2x Pt 100)
f
Voltage (0/2...10V)
Electrical connections
8.3 Connecting input INP6 2
For position feedback with 3-point stepping controller
(other selections possible in configuration level C.180).
8.4 Connecting input INP5 3
Input for process value x2 or external set-point or external
set-point offset (configuration level C.180). With voltage signals,
x2
8.5 Connecting the power supply 5
8.6 Connecting the outputs OUT2/4/5 6
8.7 Connecting output OUT1 7
A6 must be connected to the reference potential at A9.
Depending on the version, the instrument is supplied with: 90...250 V AC or 24 V UC. The
24 V UC version is for 19,2...30 V DC or 20,4...26,4 V AC. The indicated values are the limits. The
protective earth must be connected to terminal P3.
Relay outputs, corresponding to the controller output Y2 or the alarms LIM1 / LIM2 (other selections
possible in configuration level rfrom page 26).
Depending on the version, OUT1 is a relay, logic or continuous output corresponding to the
controller output Y1 (other selections in configuration level). With logic and continuous outputs, P13
must be connected to the earth terminal. The logic signal is 0 / >20 mA (load ß600 [)or0/>12V
(load ?600 [).
8.8 Digital inputs and outputs (di / do) 4890"§$
The inputs operate as current sink (IEC 1131 type1), logic „0" = -3...5 V, logic “1" = 15...30 V.
The outputs operate as „grounded load“. They are short circuit protected and contain recovery diodes.
The digital input and supply voltage (24V) must be connected on each circuit board.
4 di1 / di2 control various actions (set in configuration level C.190/ C.191 and
parameter Blck1 / Blck2)
9 di3 is used for changeover Local mode(0) i Remote mode(1).
0 di4...di7 and do1...do4 are correlated to the programmer as follows:
di4 Program STOP (0) i RUN (1) do1 Status fo control output 1
di5 Program normal (0) i RESET (1) do2 Status fo control output 2
di6 Program number (LSB) do3 Status fo control output 3
di7 Program number (MSB) do4 Status fo control output 4
di6 0 1 0/1 di8 0101
di7 0 0 1 di9 0011
program 1 2 3 parameterset 0123
" di8 / di9 is used for selecting the parameter set (bei C.700 = xx.x.3, di9 = MSB).
Operating instruction KS94 8
Electrical connections
§ di10 is the input for override control OVC+ (three-point stepping).
di11 is the input for override control OVC- (three-point stepping) or the correction of the
effective set-point OFF (0) i ON (1) (configuration level C.190 / C.191).
di12 switches the bumpless transfer of the internal set-point (tracking) OFF (0) i ON (1) or
switches from set-point w (0) i w2 (1) (configuration level C.190 / C.191).
$ do5 or do6 indicates the status automatic i manual or internal i external set-point or the
status of the controller outputs Y1 / Y2 with switching controllers (configurations C.596 / C.597).
8 The digital inputs and outputs must be supplied from one or several external 24 V dc sources
(current consumption 5 mA/input, max. load = 0,1 A/output). Examples:
Digital inputs (connect. A) Digital inputs and outputs with
one dc source (e.g. connector B)
-
+
-
+
8.9 Connecting the bus interface !
TTL level or RS422, RS485, PROFIBUS or INTERBUS. With TTL level, an interface module for
conversion to RS422/RS485 is required. 4 units may be connected to an interface module.
8.10 Connecting the inputs INP3 / INP4 %
Digital inputs and outputs with
two dc sources (e.g. connector B)
-
+
-
+
Selectable in configuration level as e.g. process variable x2, process variable x3, auxiliary variable z,
x3
ext. set-point or over ride control (OVC). The reference potential of the inputs is at C10.
8.11 Connecting the output OUT3 &
Depending on the version, OUT3 is a logic or continuous output (C.560). The logis signal is
0 / >20 mA (load ß600 [) or 0 / >12 V (load ?600 [). The signals are available, see page 28.
The function can be selected with configuration code C.560. By means of code C.565, the output
can be connected to a post processing (e.g. linearisation).
9 Operating instruction KS94
Electrical connections
8.12 Versions with integrated supply voltage
The supply voltage can be used only for energization of a 2-wire transmitter or for energization of
max. 4 control inputs. The supply voltage is potential-free and can also be used for energizing inputs
INP3 ... INP6 or for other units. Selection of supply voltage or digital inputs is by S.I.L. switches (see
figure opposite).
Transmitter
supply voltage
Ü
Position T Position D
* open
Ö
closed (T)
8.8.8.8
W2:ÀC
8.8.8.8
Y:ыыыыыо 55%
a
The supply voltage is only applied to terminals A12 and A14 with INP1 configured for
current or thermocouple (C.200; type) and the S.I.L. switches set for transmitter supply
(factory setting)! With the S.I.L. switches set to digital input, the voltage is applied to
terminals A1 and A4 independent of the configuration of input INP1. In this case, the voltage
input of INP5 is not available.
Digital input
closed (D)
open
Ü
T
Ü
D
D
*
*
Ö
T
Ö
Supply voltage for energization of
digital input (e.g. di1...di4)
External use of the supply
voltage
Connection of a 2-wire
transmitter on example of
INP1 or INP5
Operating instruction KS94 10
9. Operation (survey)
Operation (survey)
+
The user manual (order no. 9499 040 44811) is required for the complete operation.
9.1 The menues 1...3
Apart from the parameter and configuration words, the following dialogue words are used (Text1):
Text1 Signification
CBus CFrnt
Clear
Clock
Conf
End
Exit
Hold
Mark
More
OStar OStop
Para
PRun PStop
PSet PRes
Quit
PC communication via interface at terminals B12...B16 or connection on the unit front
The additional display selected at operating level is deleted (r Mark)
Adjust the clock
Transition to configuration level
Return to the previous selection menu
Return to operating level (main display)
The displayed parameter is determined as standard indication.
The displayed parameter is stored as additional display at operating level (r Clear)
The configuration level area described with MORE is accesible
Self-tuning will be started or stopped
Transition to parameter level
Programmer will be started or stopped
Programmer will be set to a specified program point or reset to the reset point
Return to operating level (main display) without storage of the values changed last
9.2 The operating level
The operating level comprises main display Ü and extension *. During the main display, automatic
or manual operation can be selected (H). With automatic, the set-point, and with manual, the
correcting value can be adjusted directly (ID). In the extension, the number and sequence of
displays is dependent of selected functions. Max. 12 parameters from the parameter level can be
displayed (Mark i Clear). Some of these parameters are directly adjustable (ID). A parameter
can be displayed continuously with the Hold function. (PressM <3sÄ Select parameter (press
ID) ÄM>3sÄ Select Hold (Press ID) ÄM). The extension can be left with Exit and M
or after a timeout of 60 s or with H. With H, the other operating mode is also selected.
+
If the set-point is set to ‘——‘ by means of D, the controller is switched off!!
Menu 1 is always selectable at operating level: deletion of additional display (Clear),
communication interface switch-over (CBus i CFrnt) and starting (OStar) or stopping
(OStop) the self-tuning, setting the clock (Clock), operate the programmer (PRun i PStop;
PRes; PSet) and transition to parameter level (Para).
11 Operating instruction KS94
Operation (survey)
+
c
0
Status display: In the extended operation of KS94, ‘Text2’ indicates the
controller status. The following table shows the possible
displays:
Set-point
Meaning Status Meaning Status Meaning
Symbol)
.....
We
Wp
xx.
y
W2
Internal set-point
External set-point
Program set-point
Segment number
Program number
2nd set-point
....
Band
End
Grw
Rset
Run
Stop
9.3 Operating the programmer:
The programmer can be operated (run, stop, reset, preset) with menu 1, via digital inputs or via the
interface (process management system).
Operating Level
No bandalarm and no
programmer active
Band width control has stopped
programmer or set-point ramp.
End of program is reached
Set-point gradient is limiting the
speed of change
Programmer in reset mode
Programmer is running
Programmer has been stopped
Menu 1
(flashes)
...
Rem
KS94 in local mode
(Front operation
possible)
KS94 in remote mode
(Front operation
blocked)
When entering the preset time (parameter setting: Pmode = 1) the time can be entered up to 99.59 in
hours . minutes, or only in hours with longer times.
9.4 Calibration:
+
a
Calibation is only possible with the controller set to manual mode. Calibration from INP1/6 (Typ=
40; Potentiometric transducer) is in two steps.
w
Select x0c Ä Press M (c blinking) Ä set transducer to 0%, wait 6s and confirm with M.
w
Select x100c Ä Press M (c blinking) Ä set transducer to 100%, wait 6s and confirm with M.
Manual calibration of INP6 is only possible with the DAC function switched off. With the DAC
function switched on, automatic calibration is possible (r DAC page 11 ).
w
For selecting YpCal , press ÄM(0 blinks) change to 1 with I and acknowledge with M
r automatic calibration is started.
Operating level
270
Man.
xw____áûô___ 12%
The parameter X0c and X100c can be allocated to the extended operating level.
10.5
+
>3s
M
I
D
End
Hold
OStar
Para
M
End
I
Signl
D
Aux
Input
Contr
Tune
Limit
Setp
M
+
I
D
I
D
End
Cal
End
INP6
INP1
+
M
M
+
I
D
I
D
End
X100c
X0c
YpCal
End
X100c
X0c
+
M
M
+
0
X0c
Operating instruction KS94 12
Operation (survey)
9.59.5 DAC – motor actuator monitoring (Digital Actor Control DAC®)
With all controllers with position feedback Yp, the motor actuator can be monitored for functional
troubles.
CFunc = 08 = 3-point stepping controller with position feedback as a potentiometer
CFunc = 09 = continuous with position feedback as a potentiometer
CFunc = 12 = continuous with current feedback via Yp (INP6)
The system detects the following stepping controller errors:
defective motor
w
defective capacitor (wrong rotating direction),
w
wrong phase followers
w
defective force transmission at spindle or drive,
w
excessive backlash due to wear
w
jamming of the control valve e.g. due to foreign body
w
With the continuous controllers, monitoring if output signal and position feedback exceed a
difference of 10 % after elapse of a 20 s filter time is provided. The DAC® function can be switched
on or off at parameter setting level (DAC = 0/1). A detected trouble is indicated, the controller
switches to manual mode and no pulses are output any more.
a
During Yp calibration, the DAC® function is activated! Otherwise, disabling would be
detected when reaching the limits and the controller would be switched to “off” (r
calibration).
9.6 Self-tuning (automatic optimization of control parameters)
After starting by the operator, the controller makes an attempt for optimization by determining the
parameters for fast line-out at the set-point without overshoot from the process characteristics.
Optimization start:the operator can start the optimization attempt at any time (see opposite drawing).
Preparation for self-tuning:
•
PID, PI, PD or P control behaviour can
be selected by the user by switching off
Tn=0 or Tv=0 before self-tuning start.
•
Determine which parameter set shall be
optimized (POpt).
Self-tuning cancelation:
The operator can cancel the optimization attempt at any time. This is possible by pressing key H
(Äcontroller switches to ‘manual’) or via OStop in menu1 (Ä controller switches to `automatic’).
The controller continues operating with the old parameter values.
•
Determine the output step change (dYopt).
•
Determine the stable correcting variable (YOptm).
•
Determine the `process-at-rest’ mode ( C.700 ; OCond)
•
Is the set-point reserve (x-w) > 10% of W100-W0?
Optimization problems:
With process conditions which prevent successful optimization, the controller cancels
the attempt for optimization (Ada F is displayed). The controller outputs are
switched off to prevent the set-point from being exceeded. Afer self-tuning
cancelation, controlling is continued with the old parameter values.
13 Operating instruction KS94
Operation (survey)
9.7 Parameter and configuration level
Menu 1 is always selectable at operating level: several operations (r 7.2) and transition to parameter
level (Para).
Menu 2 is always selectable at parameter level: selection of additional displays (Mark), return to
parameter level (End), return to operating level (Exit), transition to configuration level (Conf).
Menu 3 is always selectable at configuration level: permitting the MORE area (More), return to
configuration level (End), return to operating level without storage of the last changes (Quit)or
with storage of the changes (Exit).
Value adjustment is as follows (parameter values / configuration codes):
Example for a single value Example for combined data (e.g. C-codes)
Operating instruction KS94 14
10. Configuration
10.1 General
The KS94 controller configuration for quick and easy function selection during subsequent operation
is described in this section. During configuration, the required functions are selected from a large
variety of available functions. The configuration determines the basic structure for solution of an
application.
The configuration structure is designed so that determination of the required functions for a large
number of applications is possible by adjustment of as few configuration words as possible.
Moreover, the structure was designed flexible enough to permit additional configurations also for
realization of special applications.
10.2 Basic structure
The first menu level permits selection of the main configuration group.
The user can be guided through all function configurations, or he can configure the specific functions
required for his application directly.
Configuration
For all ‘complex’ main groups, a two-level configuration concept which enables the user to select the
‘correct’ setting for his application by defining only one configuration word was determined. If
necessary, special functions can be determined separately. For the ‘normal user’, however, the
configuration words are preset to purposeful default values! For simplification, the hierarchic
configuration dialogue is structured so that the user can and must adjust only the ‘required’
configuration words.
The user configuration dialogue is started via selector key M and ‘increment’ / ‘decrement’ keys
ID, like with the other KS92/94 operating levels:
w
Press the selector key to select menu items / input values / input positions within a ‘level’ and to
change over to the next higher level at the end of a ‘level’.
w
Press the ‘increment’ / ‘decrement’ keys for returning to a lower level and for modification of input
values.
The configuration structure is shown on the two following pages (16 and 17). All possible
configuration words are listed. Configuration words which are irrelevant for a function are not
displayed during the dialogue!
Switch-over to a selection menu is possible from anywhere during configuration by pressing key M >3s.
End: Return to configuration level
More: Activating the More function
Quit: Return to operating level
(configuration changes are not effective)
Exit: Return to operating level (configuration
changes are effective and the controller
is re-initialized).
15 Operating instruction KS94
Configuration
Fig.1: Configuration-Overview
Selector key:
Key for selection of menu item, input value and input
position
Acknowledgement and returnto menu item
Return to the previous selection menu is by
acknowledgement and End.
All configuration data shown with gray
background on the drawing are only
accessible after selection of the More
function.
Legend:
Operating instruction KS94 16
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