West Control Solutions KS 94 User Manual

Industrial controller KS 94

Operating Instruction

9499 040 44211

S94Gültig 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

8.1Notes . . . . . . . . . . . . . . . . . 7

8.2Connecting input INP1 . . . . . . . . 7

8.3	Connecting input INP6 . . .	. . . . 8
8.4	Connecting input INP5 . . .	. . . .	8
8.5	Connecting the power supply	. . . .	8

8.6Connecting 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

8.12Versions with integr. supply voltage 10

9.Operation (survey) . . . . . . . . . 11

9.1The menues 1...3 . . . . . . . . . . 11

9.2The operating level . . . . . . . . . 11

9.3Operating the programmer: . . . . . 12

9.4Calibration: . . . . . . . . . . . . 12

9.5 DAC – motor actuator monitoring . . (Digital Actor Control DAC®) . . . .13.

Symbol definition:

9.6Self-tuning (automatic optimization of control parameters) . . . . . . . . . 13

9.7Parameter and configuration level . 14

10.Configuration. . . . . . . . . . . . 15

10.1General . . . . . . . . . . . . . . . 15

10.2Basic structure. . . . . . . . . . . . 15

10.3Main groups . . . . . . . . . . . . . 18

10.4CONTR: Controller . . . . . . . . . 19

10.5SOURCE: Input signal allocation . . 21

10.6INPUT: inputs . . . . . . . . . . . . 23

10.7OUTPT: outputs . . . . . . . . . . . 27

10.8 ALARM: alarms . . . . . . . . . . 31

10.9TUNE:self-tuning . . . . . . . . . . 32

10.10DISP: User interface for operation . 32

10.11AUX: Additional functions . . . . . 33

10.12Examples of configuration . . . . . 35

11.Parameters . . . . . . . . . . . . . 36

11.1General . . . . . . . . . . . . . . . 36

11.2Set-point function . . . . . . . . . . 38

11.3Time function . . . . . . . . . . . . 38

11.4Programmer functions . . . . . . . 38

11.5 Alarm function . . . . . . . . . . . 39

11.6Self-tuning. . . . . . . . . . . . . . 39

11.7Control algorithm . . . . . . . . . . 40

11.8Input processing . . . . . . . . . . . 41

11.9Miscellaneous . . . . . . . . . . . . 42

11.10Signals . . . . . . . . . . . . . . . . 42

12. Versions . . . . . . . . . . . . . . . 43

13. . . . . . . . . . . . . . . . . . . . . 43

13.1 Input and output allocation with . . .

pre-configured units. . . . . . . . . . . . . 44

a

K J

General warning (caution, following the warnings in the instruction)

Protective earth

Earth connection

DAC® 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 Prozeund Maschinen-Automation. Subject to alterations without notice. PMA Prozessund Maschinen-Automation GmbH 2000, Printed in Germany (2003).

PMA Prozessund Maschinen-Automation GmbH • P.O.Box 310 229 • D-34058 Kassel - Germany

Front view

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

Locking screw

Display 1 e.g. Process value

Text 1 e.g. physical unit

Display 2 e.g. Set-point

Text 2 e.g. Bargraph / Dialogue

Selection key

PC interface

Increment key (z)

Manual/Automatic key

Decrement key (u)

w Locking screw: Locks the controller module in the housing.

w LEDs: indicates the statuses of controller outputs Y1, Y2 and alarms LIM1, LIM2 (other settings at configuration level C.800 r page 30).

wDisplay 1: indicatess process value at operating and parameter level, or the configuration code at configuration level.

wDisplay 2: indicates the set-point (automatic mode) or the correcting value (manual mode) in operating 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.

wText 2: indicates the output bargraph (other selections possible in configuration level C.800). Keys HDIM: For the certain function r pages 9 and 12.

wPC 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

5.Maintenance / Behaviour in case of trouble

The controller needs no maintenance. The rules to be followed in case of trouble are:

w Check mains (voltage, frequency and correct connections), w check, if all connections are correct, w check the correct funktion of the sensors and final elements, w check the configuration words for required functions and w check 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

96	96
160
	1...16

96		92 +0,8
max.	50°C	max.
min.	0°C 95% rel.
96

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 Caution! The instrument contains ESD-hazarded components.

92+0,8 ?24

1

2

Operating instruction KS94

6

Electrical connections

8.Electrical connections

galvanic isolation

*Versions with integrated supply voltage (connection example look at page 10)

8.1Notes

qThe 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).

qWhen connecting a contactor to a relay output, an RC protective circuit is necessary, to avoid voltage peaks which can cause trouble to the controller.

qIndividual or common fuse protection must be fitted (1 A per instrument).

8.2Connecting input INP1 1

Input for main process value x1 (actual value).

	a	Thermocouple	b	Resistance thermometer	c	Temperature difference (}1-}2)
x1				(Pt 100)		(2x Pt 100)
	d	Potentiometric transducer	e	Current (0/4...20mA)	f	Voltage (0/2...10V)

7	Operating instruction KS94

Electrical connections

8.3Connecting 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

x2

Input for process value x2 or external set-point or external set-point offset (configuration level C.180). With voltage signals, A6 must be connected to the reference potential at A9.

8.5Connecting the power supply 5

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.

8.6Connecting the outputs OUT2/4/5 6

Relay outputs, corresponding to the controller output Y2 or the alarms LIM1 / LIM2 (other selections possible in configuration level rfrom page 26).

8.7Connecting output OUT1 7

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 [) or 0 / >12 V (load ?600 [).

8.8Digital 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.

4di1 / 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
di7	0	0	1
program	1	2	3

di8	0	1	0	1
di9	0	0	1	1
parameterset	0	1	2	3

"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 imanual or internal iexternal set-point or the

status of the controller outputs Y1 / Y2 with switching controllers (configurations C596. / C597.).

8The 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	Digital inputs and outputs with
	one dc source (e.g. connector B)	two dc sources (e.g. connector B)

-

+

-	-	-
+	+	+

8.9Connecting 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.

8.10Connecting the inputs INP3 / INP4 %

x3

Selectable in configuration level as e.g. process variable x2, process variable x3, auxiliary variable z, ext. set-point or over ride control (OVC). The reference potential of the inputs is at C10.

8.11Connecting 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

8.12Versions 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

Digital input

supply voltage

Ü	Position T		Position D
*		open	closed (D)
Ö	closed (T)		open
				Ü
			T
			Ü
			D	*
			* D
	8.8.8.8
	W2:ÀC 8.8.8.8			Ö
	Y:ыыыыыо	55%	Ö
			T
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.

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

Operation (survey)

9.Operation (survey)

+The user manual (order no. 9499 040 44811) is required for the complete operation.

9.1The menues 1...3

Apart from the parameter and configuration words, the following dialogue words are used (Text1):

Text1		Signification
CBus	CFrnt	PC communication via interface at terminals B12...B16 or connection on the unit front
Clear		The additional display selected at operating level is deleted (rMark)
Clock		Adjust the clock
Conf		Transition to configuration level
End		Return to the previous selection menu
Exit		Return to operating level (main display)
Hold		The displayed parameter is determined as standard indication.
Mark		The displayed parameter is stored as additional display at operating level (rClear)
More		The configuration level area described with MORE is accesible
OStar	OStop	Self-tuning will be started or stopped
Para		Transition to parameter level
PRun	PStop	Programmer will be started or stopped
PSet	PRes	Programmer will be set to a specified program point or reset to the reset point
Quit		Return to operating level (main display) without storage of the values changed last

9.2The 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 < 3s Ä Select parameter (press ID) Ä M > 3s Ä Select Hold (Press ID) Ä M). 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

and acknowledge with M

Operation (survey)

Status display: In the extended operation of KS94, ‘Text2’ indicates the controller status. The following table shows the possible displays:

Set-point Meaning
Symbol)
.....	Internal set-point
We	External set-point
Wp	Program set-point

xx.Segment number

	y	Program number
	W2
		2nd set-point

Status	Meaning
....	No bandalarm and no
	programmer active
Band	Band width control has stopped
	programmer or set-point ramp.
End	End of program is reached
Grw	Set-point gradient is limiting the
	speed of change
Rset	Programmer in reset mode
Run	Programmer is running
Stop	Programmer has been stopped

Status Meaning

... KS94 in local mode (Front operation possible)

Rem KS94 in remote mode (Front operation blocked)

9.3Operating the programmer:

The programmer can be operated (run, stop, reset, preset) with menu 1, via digital inputs or via the interface (process management system).

Menu 1 (flashes)

Operating Level

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.

9.4Calibration:

+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 Ä M (0 blinks) change to 1 with I r automatic calibration is started.

Operating level				I	End		DI End			I	End
					Signl			Cal		D	X100c
a				D	Aux
	270					M		+M			X0c
					Input
			DI End								YpCal
					Contr	+
	10.5	>3s	Hold		Tune		I	End		I	End
Man.			OStar		Limit		D			D
xw____áûô___ 12%		+M	Para	M	Setp			INP1INP6	M		X0cX100c
The parameter X0c and X100c can be+allocated to the extended operating+										level.

+
M	0
M	c
+	X0c

Operating instruction KS94

12

Operation (survey)

9.5DAC – 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:

w 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

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).

9.6Self-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

•

Determine the output step change (dYopt).

be selected by the user by switching off

•

Determine the stable correcting variable (YOptm).

Tn=0 or Tv=0 before self-tuning start.

•

C700.

OCon

Determine the `process-at-rest’ mode (

;

d)

• Determine which parameter set shall be

•

Is the set-point reserve (x-w) > 10% of W100-W0?

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.

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)

9.7Parameter 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

Configuration

10.Configuration

10.1General

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.

10.2Basic 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.

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:

wPress 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’.

wPress 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

KS94 instruction Operating

16

Legend:

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.

								Configuration 1:.Fig		Configuration
								Overview-