West Control Solutions KS98-1 User Manual

PMA Prozeß- und Maschinen-Automation GmbH

KS 98-1 Multi-function unit

Engineering manual

Valid from: 1.02.2011 Order number : 9499-040-82711

û

A publication of:

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

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

Symbols used on the
instrument

Liability and warranty

Any information and notes in these operating instructions were
composed under consideration of the applicable regulations, the
present state of the art and our extensive know-how and experien
ce.

With special versions, additional ordering options or due to the la
test technical modifications, the actual scope of delivery may vary
from the descriptions and drawings in this manual.

For questions, please, contact the manufacturer.

a

Before starting to work with the instrument and be
fore commissioning, in particular, these operating
instructions must be read carefully!
The manufacturer cannot be held responsible for
damage and trouble resulting from failure to com
ply with the information given in this manual.

-

-

-

-

à

a

a

!

l

g

+

EU conformity marking

Caution, Follow the operating instructions!

Symbols in the text

Danger of injury

Danger for the instrument, or of faulty function

Danger of destroying electronic components due
to electrostatic discharge (ESD)

Additional information or reference to further
sources of information.

Important hint for avoiding frequent operator
faults.

This product may be subject to change due to im
provements of the product features in the course of
further development.

Copyright

This operating manual should be considered as confidential infor­mation, intended only for persons who work with the instrument.

Contraventions are subject to payment of damages. Further claims
reserved.

-

I-3

Content

I. Operating instruction .............................9

I-1 Description .......................................9

I-2 Safety notes .....................................10

I-3 Technical data ....................................12

I-4 Versions ........................................18

I-4.1 I/O-Modules ..................................19

I-4.2 Ex-factory setting ...............................19

I-4.3 Auxiliary equipment ..............................19

I-5 Mounting .......................................20

I-5.1 Function of wire-hook switches........................21

I-5.2 Retro-fitting and modific. of I/O-ext. (*watch connecting diagram).....22

I-5.3 I/O extension with CANopen .........................22

I-6 Electrical connections - Safety hints .......................23

I-6.1 Electromagnetic compatibility ........................23

I-6.2 Measurement earth connection........................23

I-6.3 RC protective circuitry ...........................24

I-6.4 Galvanic isolations ..............................24

I-6.5 General connecting diagram .........................24

I-6.6 Analog inputs .................................26

I-6.7 Digital in- and outputs.............................27

I-6.8 Connecting diagram i/o-modules .......................28

I-7 Commissioning ....................................29

I-8 Operation .......................................30

I-8.1 Front view ...................................30

I-8.2 Menu structure ................................31

I-8.3 Navigation, page selection ..........................32

I-8.4 Adjusting values................................33

I-9 Instrument settings in the main menu .......................34

I-9.1 CAN-Status ..................................34

I-9.2 Profibus-Status ................................34

I-9.3 ModC-Status .................................34

I-9.4 Calibration ...................................35

I-9.5 Online/Offline .................................35

I-10 Operating pages ...................................36

I-10.1 List display...................................36

I-10.2 Bargraph display................................36

I-10.3 Alarm display .................................37

I-10.4 Graphic trend curve ..............................37

I-10.5 Programmer ..................................38

I-10.6 Controller ...................................41

I-10.7 Cascade controller...............................46

I-11 Maintenance, test, trouble shooting........................48

I-11.1 Cleaning ....................................48

I-11.2 Behaviour in case of trouble .........................48

I-11.3 Shut-down ...................................48

I-11.4 Test engineering as basic equipment.....................48

I-11.5 I/O-Test ....................................50

I-3

II. Engineering-Tool ...............................51

II-1 Survey .........................................51

II-1.1 Scope of delivery ...............................51

II-2 Installation ......................................52

II-2.1 Hardware and software prerequisites ....................52

II-2.2 Software installation .............................52

II-2.3 Licencing....................................53

II-2.4 Software start .................................53

II-3 Menu reference to the engineering tool .....................54

II-3.1 Menu ‘File’...................................54

II-3.2 Menu ‘Edit’ ..................................60

II-3.3 Menu ‘Functions’ ...............................63

II-3.4 Menu ‘Fixed funct.’ ..............................63

II-3.5 Menu ‘Device’ .................................64

II-3.6 Menu ‘Options’ ................................65

II-3.7 Menu ‘Window’ ................................67

II-3.8 Menu ‘Help’ ..................................67

II-4 Engineering tool operation .............................68

II-4.1 Fundamentals of the engineering tool operation ..............68

II-4.2 Function block placement ...........................68

II-4.3 Function block shifting ............................68

II-4.4 Creating connections .............................69

II-4.5 Online operation................................71

II-4.6 Trend function .................................72

II-5 Building an engineering...............................77

II-6 Tips and tricks ....................................81

II-6.1 Function keys .................................81

II-6.2 Mouse key functions .............................82

II-6.3 Tips and tricks .................................83

III. Function blocks: ...............................89

III-1 Scaling and calculating functions.........................91

III-1.1 ABSV (absolute value (No. 01)) ........................91

III-1.2 ADSU ( addition/subtraction (No. 03)) ....................91

III-1.3 MUDI ( Multiplication / division (No. 05))...................92

III-1.4 SQRT ( square root function (No. 08)) .....................92

III-1.5 SCAL ( scaling (No. 09)) ............................93

III-1.6 10EXP (10s exponent (No. 10)) ........................93

III-1.7 EEXP (e-function (No. 11)) ...........................94

III-1.8 LN (natural logarithm (No. 12)) ........................94

III-1.9 LG10 (10s logarithm (No. 13)) .........................95

III-2 Non-linear functions.................................96

III-2.1 LINEAR (linearization function (No. 07)) ...................96

III-2.2 GAP (dead band (No. 20)) ...........................98

III-2.3 CHAR (function generator (No. 21)) ......................99

III-3 Trigonometric functions ..............................100

III-3.1 SIN (sinus function (No. 80)) .........................100

III-3.2 COS (cosinus function (No. 81)) .......................100

III-3.3 TAN (tangent function (No. 82)) .......................101

I-4

III-3.4 COT (cotangent function (No. 83)) ......................102

III-3.5 ARCSIN (arcus sinus function (No. 84)) ...................103

III-3.6 ARCCOS (arcus cosinus function (No. 85))..................104

III-3.7 ARCTAN (arcus tangent function (No. 86)) .................105

III-3.8 ARCCOT (arcus cotangent function (No. 87)) ................105

III-4 Logic functions ...................................106

III-4.1 AND (AND gate (No. 60)) ..........................106

III-4.2 NOT (inverter (No. 61)) ............................106

III-4.3 OR (OR gate (No. 62)) ............................107

III-4.4 BOUNCE (debouncer (No. 63)) ........................108

III-4.5 EXOR (exclusive OR gate (No. 64))......................108

III-4.6 FLIP (D flipflop (No. 65)) ...........................109

III-4.7 MONO (monoflop (No. 66))..........................110

III-4.8 STEP (step function for sequencing (No. 68)) ................111

III-4.9 TIME1 (timer (No. 69)) ............................112

III-5 Signal converters ..................................114

III-5.1 AOCTET (data type conversion (No. 02))...................114

III-5.2 ABIN (analog i binary conversion (No. 71)) ................115

III-5.3 TRUNC (integer portion (No. 72)) ......................117

III-5.4 PULS (analog pulse conversion (No. 73)) ..................118

III-5.5 COUN (up/down counter (No. 74)) ......................120

III-5.6 MEAN (mean value formation (No. 75)) ...................122

III-6 Time functions....................................124

III-6.1 LEAD ( differentiator (No. 50)) ........................124

III-6.2 INTE (integrator (No. 51)) ..........................126

III-6.3 LAG1 ( filter (No. 52)).............................128

III-6.4 DELA1 ( delay time (No. 53)) .........................129

III-6.5 DELA2 ( delay time (No. 54) ) ........................130

III-6.6 FILT ( filter with tolerance band (No. 55) ) ..................131

III-6.7 TIMER ( timer (No. 67) ) ...........................132

III-6.8 TIME2 ( timer (No. 70) ) ...........................133

III-7 Selecting and storage ...............................134

III-7.1 EXTR ( extreme value selection (No. 30)) ..................134

III-7.2 PEAK ( peak value memory (No. 31)).....................135

III-7.3 TRST ( hold amplifier (No. 32))........................136

III-7.4 SELC ( Constant selection (No. 33)) .....................136

III-7.5 SELD (selection of digital variables - function no. 06) ...........137

III-7.6 SELP ( parameter selection (No. 34)) ....................138

III-7.7 SELV1 ( variable selection (No. 35)) .....................139

III-7.8 SOUT ( Selection of output (No. 36)).....................140

III-7.9 REZEPT ( recipe management (No. 37)) ...................141

III-7.10 2OF3 ( 2-out-of-3 selection with mean value formation (No. 38)) .....143

III-7.11 SELV2 ( cascadable selection of variables (No. 39)) ............145

III-8 Limit value signalling and limiting ........................146

III-8.1 ALLP ( alarm and limiting with fixed limits(No. 40)).............146

III-8.2 ALLV ( alarm and limiting with variable limits (No. 41))...........148

III-8.3 EQUAL ( comparison (No. 42) )........................150

III-8.4 VELO ( rate-of-change limiting (No. 43) ) ..................151

III-8.5 LIMIT ( multiple alarm (No. 44)) .......................152

III-8.6 ALARM ( alarm processing (No. 45) )

....................153

I-5

III-9 Visualization .....................................154

III-9.1 TEXT (text container with language-dependent selection (No. 79)) ....154

III-9.2 VWERT ( display / definition of process values (No. 96) )..........156

III-9.3 VBAR ( bargraph display (No. 97) )......................161

III-9.4 VPARA ( parameter operation (No. 98) ) ...................164

III-9.5 VTREND ( trend display(No. 99) ) ......................166

III-10 Communication ...................................169

III-10.1 L1READ ( read level1 data(No. 100) ) ....................169

III-10.2 L1WRIT ( write level1 data (No. 101)) ....................170

III-10.3 DPREAD ( read level1 data via PROFIBUS (No. 102) ) ............171

III-10.4 DPWRIT ( write level1 data via PROFIBUS (No. 103)) ............172

III-10.5 MBDATA (read and write parameter data via MODBUS - no. 104) ....173

III-11 I/O extensions with CANopen...........................175

III-11.1 RM 211, RM212 and RM213 basic modules ................175

III-11.2 C_RM2x (CANopen fieldbuscoupler RM 201 (No. 14)) ...........176

III-11.3 RM_DI (RM 200 - (digital input module (No. 15)) ..............177

III-11.4 RM_DO (RM 200 - digital output module (No. 16)) .............177

III-11.5 RM_AI (RM200 - analog input module (No. 17)) ..............178

III-11.6 RM_AO (RM200 - analog output module (No. 18)) .............180

III-11.7 RM_DMS (strain gauge module (No. 22)) ..................181

III-12 KS 98-1- KS 98-1 cross communication (CANopen) ..............183

III-12.1 CRCV (receive mod. block no's 22,24,26,28 (No.56)) ............183

III-12.2 CSEND (Send mod. blockno.'s 21, 23, 25, 27 - (No. 57)) ..........184

III-13 Connection of KS 800 and KS 816 .........................185

III-13.1 C_KS8x (KS 800 and KS 816 node function - (No. 58)) ...........186

III-13.2 KS8x (KS 800/ KS 816 controller function - (No. 59)) ............187

III-14 Description of KS 98-1 CAN bus extension ...................189

III-14.1 CPREAD (CAN-PDO read function (No. 88)) .................193

III-14.2 CPWRIT (CAN-PDO write function (No. 89)) ................194

III-14.3 CSDO (CAN-SDO function (No. 92)) ....................195

III-15 Programmer .....................................201

III-15.1 APROG ( analog programmer (No. 24)) / APROGD ( APROG data (No. 25)) . 201
III-15.2 DPROG ( digital programmer (No. 27)) / DPROGD ( DPROG data(No. 28)) . 219

III-16 Controller.......................................223

III-16.1 CONTR (Controllerfunction with one parameterset (No. 90)) ........223

III-16.2 CONTR+ (Controllerfunction with six parametersets (No. 91)) .......224

III-16.3 Parameter and Konfiguration for CONTR, CONTR+ .............226

III-16.4 Control behaviour ..............................228

III-16.5 Optimizing the controller...........................240

III-16.6 Empirical optimization ............................241

III-16.7 Self-tuning r controller adaptation to the process ............242

III-16.8 PIDMA (Control function with particular self-tuning behaviour (No. 93) .....247

III-16.9 Parameter and configuration for PIDMA ..................250

III-16.10 Controller characteristics and self-tuning with PIDMA ...........252

III-16.11 Controller applications: ...........................256

III-16.12 Setpoint functions ..............................260

III-16.13 Process value calculation ..........................265

III-16.14 Small controller ABC ...........................271

III-17 Inputs .........................................274

I-6

III-17.1 AINP1 ( analog input 1 (No. 08)) .......................274

III-17.2 AINP3...AINP5 ( analog inputs 3...5 (No. 112...114) ) ............281

III-17.3 AINP6 ( analog input 6 (No. 115)) ......................282

III-17.4 DINPUT ( digital inputs (No. 121)) ......................285

III-18 Outputs ........................................286

III-18.1 OUT1 and OUT2 ( process outputs 1 and 2 (No. 116, 117)).........286

III-18.2 OUT3 ( process output 3 (No. 118)).....................287

III-18.3 OUT4 and OUT5 ( process outputs 4 and 5 (No. 119...120))........288

III-18.4 DIGOUT ( digital outputs (No. 122)).....................289

III-19 Additional functions ................................290

III-19.1 LED (LED display (No. 123)).........................290

III-19.2 CONST ( constant function (No. 126) )...................291

III-19.3 INFO ( information function (No. 124) )...................292

III-19.4 STATUS ( status function (No. 125)).....................293

III-19.5 CALLPG (Function for calling up an operating page (no. 127)) .......296

III-19.6 SAFE ( safety function (No. 94)).......................297

III-19.7 VALARM (display of all alarms on alarm operating pages (function no. 109)298

III-20 Modular I/O - extension-modules ........................300

III-20.1 TC_INP (analog input card TC, mV, mA) ...................300

III-20.2 F_Inp (frequency/counter input) .......................302

III-20.3 R_Inp (analog input card ) ..........................303

III-20.4 U_INP (analog input card -50...1500mV, 0...10V) ..............305

III-20.5 I_OUT (analog output card 0/4...20mA, +/-20mA) .............307

III-20.6 U_OUT (analog output card 0/2...10V, +/-10V) ...............308

III-20.7 DIDO (digital input/output card) .......................309

III-21 Function management ...............................310

III-21.1 Memory requirement and calculation time .................310

III-21.2 Sampling intervals ..............................311

III-21.3 EEPROM data ................................311

III-22 Examples.......................................312

III-22.1 Useful small engineerings ..........................312

III-22.2 Controller applications ............................313

III-23 Index .........................................314

I-7

Preface

This manual consists of three parts.

I. Operating instructions

II. Engineeringtool description

III. Function block description

Section I holds the required information for identification, mounting, connection and electrical commissioning of the
unit under consideration of safety notes of the application and environmental conditions.

The basic principles of operation are explained: Controls and indicators, menu structure and navigation with the cursor,
selection of sub-menus and properties as well as adjustment of e.g. s and parameters.

Section II comprises the handling of the engineering-tool, the building of a simple engineering and transmission to the
KS 98-1.

9499-040-82711

+

+

Section III presents the particular fnction blocks in detail.

For functional commissioning, additional descriptions are required; please, order them separately or load them from
the PMA homepage: www.pma-online.de

As the functions provided in KS 98-1 are composed individually for each application using an Engineering Tool
ET/KS 98, entire comprehension of the operating functions requires the relevant Project description with the Enginee ­ring !

Supplementary documentation:

PROFIBUS-protocol (GB) 9499-040-82811
ISO 1745-protocol (GB) 9499-040-82911

I-8

9499-040-82711 Description

I Operating instruction

I-1 Description

1

2

KS 98-1 advanced

4

3

Fig. 1 Frontview

The instrument is a compact automation unit the function of which can be configured freely by means of function
blocks. Each unit contains a comprehensive function library for selection, configuration, parameter setting and connec ­tion of max. 450 function blocks by means of an engineering tool.

I.e. complex mathematical calculations, multi-channel control structures and sequence controllers can be realized in a
single unit.

Various operating pages are indicated via the front-panel LCD matrix display, e.g.

Numeric input and output of analog and digital signals, values and parameters as well as

w

full-graphics display of bargraphs, controllers, programmers and trends.

w

Display colour red / green and direct / inverse display can be switched over dependent on event, or by operation

w

dependent on the engineering.

Dependent on version, the basic unit is equipped with analog and digital inputs, outputs and relays.

Additional inputs and outputs are available either with option C or “modular option C”, which contains four sockets for
various I/O modules.

Optionally, the unit may be equipped with 2 additional communication interfaces:

Option B: serial TTL/RS422 interface or Profibus-DP

w

Option CAN: CANopen-compliant interface port for the I/O extension with modular I/O system RM200

w

I-9

Safety notes 9499-040-82711

The user is responsible that the instrument is operated only by

I-2 Safety notes

This section provides a survey of all important safety aspects: op
timum protection of personnel and safe, trouble-free operation of
the instrument.

Additionally, the individual chapters include specific safety notes
for prevention of immediate hazards, which are marked with sym
bols. Moreover, the hints and warnings given on labels and in
scriptions on the instruments must be followed and kept in
readable condition continuously.

General

Software and hardware are programmed or developed in compli
ance with the state of the art applicable at the time of develop
ment, and considered as safe.

Before starting to work, any person in charge of work at the prod
uct must have read and understood the operating instructions.

trained and authorized persons. Maintenance and repair may be
done only by trained and specialized persons who are familiar

-

with the related hazards.

Operation and maintenance of the instrument are limited to reli
able persons. Any acts susceptible to impair the safety of persons
or of the environment have to be omitted. Any persons who are
under effect of drugs, alcohol or medication affecting reaction are

­precluded from operation of the instrument.

-

Instrument Safety

This instrument was built and tested according to VDE 0411 /
EN61010-1 and was shipped in safe condition. The unit was
tested before delivery and has passed the tests required in the

­test plan.

-

In order to maintain this condition and to ensure safe operation,
the user must follow the hints and warnings given in these safety

­notes and operating instructions.

-

The plant owner is recommended to request evidence for knowl
edge of the operating instructions by the personnel.

-

Correct use for intended application

The operating safety is only ensured when using the products cor­rectly for the intended application. The instrument can be used as
a multiple function controller for open and closed control loops in
industrial areas within the limits of the specified technical data
and environmental conditions.

Any application beyond these limits is prohibited and considered
as non-compliant.

Claims of any kind against the manufacturer and /or his lawful
agents, for damage resulting from non-compliant use of the instru
ment are precluded, liability is limited to the user.

User responsibility

The user is responsible:

for keeping the operating manual in the immediate vicinity

w

of the instrument and always accessible for the operating
personnel.

for using the instrument only in technically perfect and safe

w

condition.

Apart from the work safety notes given in these operating instruc
tions, compliance with the generally applicable regulations for
safety, accident prevention and environment protection is compul
sory.

The user and the personnel authorized by the user are responsible
for perfect functioning of the instrument and for clear definition of
competences related to instrument operation and maintenance.
The information in the operating manual must be followed com
pletely and without restrictions!

-

The unit is intended exclusively for use as a measuring and control
instrument in technical installations.

The insulation meets standard EN 61010-1 with the values for
overvoltage category, degree of contamination, operating voltage
range and protection class specified in the operating instructions /
data sheet.

The instrument may be operated within the specified environmen­tal conditions (see data sheet) without impairing its safety.

The instrument is intended for mounting in an enclosure. Its con­tact safety is ensured by installation in a housing or switch cabi­net.

Unpacking the instrument

­Remove instrument and accessories from the packing. Enclosed

standard accessories:

–

operating notes or operating instructions

–

fixing elements.

Check, if the shipment is correct and complete and if the instru
ment was damaged by improper handling during transport and
storage.

!

-

We recommend to keep the original packing for shipment in case

­of maintenance or repair.

Warning!
If the instrument is so heavily damaged that safe operati
on seems impossible, the instrument must not be taken
into operation.

-

-

I-10

9499-040-82711 Safety notes

Mounting

Mounting is done in dustfree and dry rooms.
The ambient temperature at the place of installation must not ex

ceed the permissible limits for specified accuracy given in the
technical data. When mounting several units with high packing
density, sufficient heat dissipation to ensure perfect operation is
required.

For installation of the unit, use the fixing clamps delivered with
the unit.

The sealing devices (e.g. sealing ring) required for the relevant
protection type must also be fitted.

Electrical connections

All electrical wiring must conform to local standards
(e.g. VDE 0100 in Germany). The input leads must be kept separate
from signal and mains leads.

The protective earth must be connected to the relevant terminal
(in the instrument carrier). The cable screening must be connected
to the terminal for grounded measurement. In order to prevent
stray electric interference, we recommend using twisted and
screened input leads.

The electrical connections must be made according to the relevant
connecting diagrams.

See electrical safety, page 23

Electrical safety

The insulation of the instrument meets standard EN 61 010-1 (VDE
0411-1) with contamination degree 2, overvoltage category III,
working voltage 300 V r.m.s. and protection class I.

Galvanically isolated connection groups are marked by lines in the
connecting diagram.

Commissioning

Before instrument switch- on, ensure that the rules given below
were followed:

Ensure that the supply voltage corresponds to the specifica

w

tion on the type label.

All covers required for contact safety must be fitted.

w

Before instrument switch- on, check if other equipment and

w

/ or facilities connected in the same signal loop is / are not
affected. If necessary, appropriate measures must be taken.

On instruments with protection class I, the protective earth

w

must be connected conductingly with the relevant terminal
in the instrument carrier.

Operation

Switch on the supply voltage. The instrument is now ready for op
eration. If necessary, a warm- up time of approx. 1.5 min. should

­be taken into account.

a

Warning !
Any interruption of the protective earth in the in
strument carrier can impair the instrument safety.
Purposeful interruption is not permissible.
If the instrument is damaged to an extent that
safe operation seems impossible, shut it down
and protect it against accidental operation.

Shut- down

For permanent shut- down, disconnect the instrument from all
voltage sources and protect it against accidental operation.

Before instrument switch- off, check that other equipment and / or
facilities connected in the same signal loop is / are not affected. If
necessary, appropriate measures must be taken.

Maintenance and modification

The instrument needs no particular maintenance.
Modifications, maintenance and repair may be carried out only by

trained, authorized persons. For this, the user is invited to contact
the service.

For correct adjustment of wire-hook switches (page 21 ) and for in­stallation of modular option C, the unit must be withdrawn from
the housing.

a

Before carrying out such work, the instrument must be discon
nected from all voltage sources.

After completing such work, re- shut the instrument and re-fit all

­covers and components. Check, if the specifications on the type la
bel are still correct, and change them, if necessary.

Warning!
When opening the instruments, or when remo
ving covers or components, live parts or termi
nals can be exposed.

Explosion protection

Non-intrinsically safe instruments must not be operated in explo
sion-hazarded areas. Moreover, the output and input circuits of
the instrument / instrument carrier must not lead into explo
sion-hazarded areas.

-

-

-

-

-

-

-

-

The instrument must be operated only when mounted in its

w

enclosure.

I-11

Technical data 9499-040-82711

I-3 Technical data

General

Housing

Plug-in module, inserted from front.
Material: Makrolon 9415, flame-retardant, self-extinguishing
Flammability class: UL 94 VO

Front-panel / display

160 x 80-dot LCD matrix display
4 LEDs, 4 foil-covered keys

Front interface port (standard)

Front-panel socket for PC adapter
(see „Accessories“ page 19).

Protection mode

(to EN 60 529, DINVDE 0470)
Front: IP 65
Housing: IP 20
Terminals: IP 00

Safety tests

Complies with EN 61 010-1

Overvoltage category: III

w

Contamination class: 2

w

Working voltage range: 300 VAC

w

Protection class: I

w

Electrical connections

Screw terminals for conductor cross-section from 0,5 - 2,5 mm

Mounting method

Panel mounting with 4 fixing clamps at top/bottom

Mounting position

Not critical

Weight

Approx. 0.75 kg with all options

Environmental conditions

Permissible temperatures

For operation: 0...55°C
For specified accuracy: 0...60°C, optionC
For UL-Devices: Operation and protected operation 0...50°C
Storage and transport: –20...60 °C

Temperature effect: £ 0.15% / 10 K

Climatic category

KUF to DIN 40 040
Relative humidity: £ 75% yearly average, no condensation

Shock and vibration

Vibration test Fc: To DIN 68-2-6 (10...150 Hz)
Unit in operation: 1g or 0.075 mm,
Unit not in operation: 2g or 0.15 mm
Shock test Ea:To DIN IEC 68-2-27 (15g, 11 ms)

2

DIN EN 14597

The device may be used as temperature control and limiting equip
ment according to DIN EN 14597.

CE marking

Meets the EuropeanDirectives regarding „Electromagnetic Compa
tibility“ and „Low-voltage equipment“(r page 23)

The unit meets the following European guidelines:

q

Electromagnetic compatibility (EMC): 89/336/EEC
(as amended by 93/97/EEC)

q

Electrical apparatus (low-voltage guideline):
73/23/EEC (as amended by 93/68/EEC).

Evidence of conformity is provided by compliance with EN 61326-1
and EN 61010-1

cULus certification

cULus-certification

(Type 1, indoor use) File: E 208286

a

RC protective circuitry must be fitted with inducti
ve load !

-

-

-

I-12

9499-040-82711 Technical data

Connections

Depending on version and selected options, the following inputs
and outputs are available:

DI DO AI AO

4 relays

di1*

or

2 relays

+

2AO

OPTION B

OPTION C*

or

modular

OPTION C*

Not available with option CAN!

*

di2*

di1*
di2*

di3
di4

di5
di6
di7

di8

di9

di10
di11
di12

OUT1
OUT2
OUT4

OUT5

OUT4
OUT5

do1
do2
do3

do4

do5
do6

INP1
INP5
INP6

INP1
INP5
INP6

––

INP3
INP4

Depending on module type

–

OUT1
OUT2

OUT3

Inputs

Resistance thermometer

Pt 100 to DIN IEC 751, and temperature difference2xPt100

Range Error Resolution

–200.0...250.0 °C £ 0.5 K 0.024 K

–200.0...850.0 °C £ 1.0 K 0.05 K
2 x –200.0...250.0 °C £ 0.5 K 0.024 K
2 x –200.0...250.0 °C £ 0.1 K 0.05 K

Linearization in °C or ° F
Two wire connection with compensation or three-wire connection

without.
Two-wire connection with lead resistance adjustment.
Lead resistance: £ 30 W per lead
Sensor current: £ 1mA
Input circuit monitoring for sensor/lead break, and lead short circuit.

Potentiometric transducer

R

incl. 2 x R

total

L

0...500 W£0.1 % £ 0.02 W

Resistance-linear
Sensor current: £ 1mA
Matching/scaling with sensor connected.
Input circuit monitoring for sensor/lead break, and lead short circuit.

Error Resolution

Universal input INP1

Limiting frequency: fg=1Hz,Measurementcycle: 200 ms

Thermocouples

according to DIN IEC 584

Type Range Error Resolution
L –200...900°C £ 2K 0,05 K
J –200...900°C £ 2 K 0,05 K
K –200...1350°C £ 2 K 0,072 K
N –200...1300°C £ 2 K 0,08 K
S –50...1760°C £ 3 K 0,275 K
R –50...1760°C £ 3 K 0,244 K

1)

B

(25)400...1820°C £ 3 K 0,132 K

T –200.. .400°C £ 2 K 0,056 K

2)

W(C)
E –200... 900°C £ 2 K 0,038 K

With linearization (temperature-linear in °C or °F)
Input resistance: ³ 1MW
Cold-junction compensation (CJC): built in

Input circuit monitor:

Current through sensor: £ 1mA
Reverse-polarity monitor is triggered at 10 °C below span start.

Additional error of internal CJC

£ 0.5 K per 10 K terminal temperature External temperature
selectable: 0...60 °C or 32...140 °F

0...2300°C £ 2 K 0,18 K

*

1 ) from 400 °C

*

2 ) W5Re/W26Re

Resistance input

Range Error Resolution

0...250 W£0.25 W < 0.01 W

0...500 W£0.5 W < 0.02 W

Direct current 0/4...20mA

Range Error Resolution
0/4...20 mA £ 0.1 % £ 0.8 mA

Input resistance: 50 W
Input circuit monitor with 4...20mA: triggered when I £ 2mA

Direct voltage

Range Error Resolution
0/2...10 V £ 0.1 % £ 0.4 mV

Input resistance ³ 100 kW

I-13

Technical data 9499-040-82711

Signal input INP5
Differential amplifier input

Up to 6 controllers can be cascaded, if there is no other galvanic
connection between them. If there is, only 2 inputs can be cascaded.

Direct current and voltage

Technical data as for INP1, except for:
Limiting frequency: = 0.25 Hz, Measurement cycle: 800 ms
Input resistance (voltage): ³ 500 kW

Signal input INP6

Limiting frequency: = 0.5 Hz, Measurement cycle: 400 ms

Potentiometric transducer

Technical data as for INP1, except for:

R

inkl. 2 x RL Error Resolution

total

0...1000 W£0.1 % £ 0.04 W

Direct current 0/4...20 mA

Technical data as for INP1

Signal inputs INP3, INP4 (option C)

Galvanically-isolated differential amplifier inputs.
Limiting frequency: fg = 1 Hz, Measurement cycle: 100 ms

Direct current

Technical data as for INP1, except Ri = 43 W

Outputs

Relay outputs (OUT4, OUT5)

Relays have potential-free change-over contacts.
Max. contact rating:
500 VA, 250 V, 2 A with 48...62 Hz, cosj³0,9
Minimum rating: 12 V, 10 mA AC/DC
Number of switching cycles electrical: for I = 1A/2A ³ 800,000 /

500,000 (at ~ 250V / (resistive load))

When connecting a contactor to a relay output, RC

!

protective circuitry to specification of the contactor
manufacturer is required. Varistor protection is not
recommended!

Outputs OUT1, OUT2

Relay or current/logic signal, depending on version:

OUT1, OUT2 as current outputs

Galvanically isolated from the inputs
0/4...20 mA, selectable
Signal range: 0...22 mA
Resolution: £ 6mA (12 bits)
Error: £ 0.5%
Load: £ 600 W
Load effect: < 0.1%
Limiting frequency: approx. 1 Hz Output cycle: 100ms

Control inputs di1...di12

di1, di2: standard
di3...d7: Option B
di8...di12: Option C

Opto-coupler

Nominal voltage: 24 VDC, external
Current sink (IEC 1131 Type 1)
Logic „0“ (Low): –3...5 V, Logic „1“ (High): 15...30 V
Current demand: approx. 6 mA (for galvanic connections and isola

tion see page 25).

Built-in transmitter supply (optional)

Can be used to energize a two-wire transmitter or up to 4
opto-coupler inputs.Galvanically isolated.

Output: ³ 17.5 VDC, max. 22 mA
Short-circuit proof.

Factory setting

The transmitter supply is available at terminals A12 and A14

+

See page 25, Configuration see page 21

OUT1, OUT2 as logic signal

0/³ 20 mA with a load ³ 600 W
0 / > 12 V with a load ³ 600 W

Output OUT3 (Option C)

Technical data as for OUT1, OUT2, as current output

Control outputs do1..do6

Galvanic isolated Opto-coupler outputs, galvanic isolation see

­page 25 and text.

Grounded load: common positive control voltage

Switch rating: 18...32 VDC; Imax £ 70 mA
Internal voltage drop: £ 0.7V with I

Protective circuit: thermal, switches off with overload.
Supply 24 V DC external
Residual ripple £ 5%

ss

max

I-14

9499-040-82711 Technical data

Modular Option C

Each module has two channels which can be configured independently.

A/D-Converter

Resolution: 20,000 (50Hz) or 16,667 (60Hz) steps for the selected
measuring range.

Conversion time: 20ms (50Hz) or 16.7ms (60Hz).

D/A-Converter

Resolution:12Bit
Refresh-Rate: 100 ms

Cut-off frequency

Analog: fg=10Hz
Digital: fg=2Hz
Measurement cycle: 100 ms per module

R_INP Resistive input module

(9407-998-0x201)
Connection method: 2, 3 or 4-wire circuit (with 3 und 4-wire con

nection, only one channel can be used).

Sensor current:

£ 0,25mA

Resistance thermometer

Type Range °C Overall error Resolution K/Digit
Pt100 -200...850°C £ 2 K 0,071
Pt100 -200...100°C £ 2 K 0,022
Pt1000 -200...850°C £ 2 K 0,071
Pt1000 -200...100°C £ 2 K 0,022
Ni100 -60...180°C £ 2 K 0,039
Ni1000 -60...180°C £ 2 K 0,039

Linearization: in °C oder °F

Lead resistance

Pt (-200...850°C): £ 30
Pt (-200...100°C), Ni: £ 10

Lead resistance compensation

3 and 4-wire connection: not necessary.
2-wire connection: compensation via the front with short-circuited

sensor. The calibration values are stored in a non-volatile memory.

Lead resistance effect

3 and 4-wire connection: negligible

Sensor monitoring

Break: sensor or lead. Short-circuit: triggers at 20 K below mea
suring range.

Resistance / Potentiometer

Range R

0...160 W

0...450 W

0...1600 W

0...4500 W

ges

/ W

W per lead

W per lead

Overall error

£ 1% 0,012
£ 1% 0,025
£ 1% 0,089
£ 1% 0,025

-

Resolution W/Digit

Characteristic: resistance-linear
Lead resistance or 0%/100% compensation:

via the front with short-circuited sensor. The calibration values are
stored in a non-volatile memory.

Variable resistance (only 2-wire connection): compensation for 0%

w

Potentiometer: compensation for 0% and 100%

w

Lead resistance effect

3 and 4-wire connection: negligible

Sensor monitoring:

break: sensor or lead

TC_INP Thermocouple, mV, mA Module

(9407-998-0x211)

Thermocouples

To DIN IEC 60584 (except L, W/C, D)

Type Range

L

­J

K

N
S
R

(1)

B

T

W(C)

D

E

*

(1) Values apply from 400°C

-200...900°C

-200...900°C

-200...1350°C

-200...1300°C

-50...1760°C

-50...1760°C

(25) 400...1820°C

-200...400°C

0...2300°C

0...2300°C

-200...900°C

Overall

error

£ 2 K 0,080
£ 2 K 0,082
£ 2 K 0,114
£ 2 K 0,129
£ 3 K 0,132
£ 3 K 0,117
£ 3 K 0,184
£ 2 K 0,031
£ 2 K 0,277
£ 2 K 0,260
£ 2 K 0,063

Linearization:in°Cor°F
Linearity error: negligible

Input resistance:

³1MW

Temp. compensation (CJC): built in

£ 0.5K/10K

Error:
External CJC possible: 0...60 °C or. 32...140 °F
Source resistance effect: 1mV/kW

Sensor monitoring:

Sensor current:

£ 1mA

Reversed polarity monitor: triggers at 10K below measuring range

mV input

Range

0...30 mV

0...100 mV

0...300 mV

Input resistance: ³1MW
Break monitoring: built in. Sensor current: £1mA

Overall error Resolution

£ 45 mV 1,7 mV
£ 150 mV 5,6 mV
£ 450 mV 17 mV

K/Digit

I-15

Technical data 9499-040-82711

mA input

Range
0/4...20 mA

Input resistance:10W
Break monitor:<2mA (only for 4...20 mA)
Over range monitor: >22mA

Overall error

£ 40 mA 2 mA

Resolution

U_INP High-impedance voltage input

(9407-998-0x221)

Range

-50...1500 mV

0...10 V

Characteristic: voltage-linear
Input resistance: >1G
Source resistance effect: £ 0,25 mV/MW
Sensor monitoring: none

Overall error Resolution mV/Digit

£ 1,5 mV 0,09

£ 10 mV 0,56

W

U_OUT Voltage output module

(9407-998-0x301)

Signal ranges: 0/2...10V, -10...10V configurable
Resolution: approx.. 5.4 mV/digit
Load: ³ 2kW

Load effect : £ 0.1%

I_OUT Current output module

(9407-998-0x311)

Signal ranges: 0/4...20mA, -20...20mA configurable by channel
Resolution: ca. 11mA/Digit
Load: £ 400 W

Load effect: £ 0.1%/100W

F_INP Frequency/counter Module

(9407-998-0x411)

Current sink: to IEC 1131 Type 1

Logic „0“: -3...5V
Logic „1“: 15...30V

Galvanic isolation: via Opto-couplers
Nominal voltage: 24 VDC external
Input resistance:12k
Selectable functions:

Control input (2 channels)

w

Pulse counter (2 channels)

w

Frequency counter (2 channels)

w

Up/down counter (1 channel)

w

Quadrature counter (1 channel)

w

Frequency range:
Signal shape: any (square 1:1 with 20kHz)
Gate time: 0.1...20s adjustable (only relevant with frequency mea

surement)

W

£ 20 kHz

-

Influencing factors

Temperature effect: £ 0,1%/10K
Supply voltage: negligible
Common mode interference: negligible up to 50 Vrms
Series mode interference: negligible up to 300 mVrms (TC),

30 mVrms (RT), 10 Vrms (U), 5 Vrms (F)

CAN I/O extension

The unit offers a port conforming to CANopen for connection of
the RM 200 system and of KS 800 or additional KS 98-1 units with
max. five CAN nodes.

DIDO Digital I/O Module

(9407-998-0x401)

Number of channels: 2 (configurable as input or output by channel)

Input

Current sink: to IEC 1131 Type 1)
Logic „0“: -3...5V, Logic „1“: 15...30V

Measurement cycle: 100 ms
Galvanic isolation : via opto-couplers
Nominal voltage: 24 VDC external

Input resistance:5k

W

Output

Grounded load (common positive control voltage)

Switch rating: 18...32 VDC;
Internal voltage drop:
Refresh-Rate: 100 ms
Galvanic isolation : via opto-couplers
Protective circuit: thermal, switches off with overload.

I-16

£70 mA

£ 0.7 V

+
+

Control inputs di1 and di2 are not available !

Modular option C is not available

Power supply

Dependent on version:

Alternating current

90...250 VAC
Frequency: 48...62 Hz
Power consumption: approx. 17,1 VA; 9,7 W (max. configuration).

Universal current 24 V UC

24 VAC, 48...62 Hz/24 VDC
Tolerance: +10...–15% AC 18...31.2 VDC
Power consumption AC: approx. 14.1 VA; 9.5 W
DC: 9,1 W (max. Configuration).

9499-040-82711 Technical data

Behaviour after power failure

Storage in non-volatile EEPROM for structure, configuration, pa
rameter setting and adjusted setpoints.

Storage in a capacitor-buffered RAM (typ. > 15 minutes) for data
of time functions (programmers, integrators, counters, ...)

-

Real-time clock(Option B, RS 422)

Buffer capacitor provides back-up for at least 2 days (typical).

Bus interface (Option B)

TTL and RS422 / 485-interface

Galvanically isolated, choice of TTL or
RS 422/485 operation.

Number of multi function unitsper bus:

With RS 422/485: 99
With TTL signals: 32 interface modules (9404 429 980x1). Address

range ((00...99)See Documentation 9499-040-82911) .

PROFIBUS-DP interface

According to EN 50 170, Vol. 2.
Reading and writing of all process data, parameters, and configu-

ration data.

Transmission speeds and cable lengths

automatic transm. speed detection, 9,6 kbit/s ...12 Mbit/s

Addresses

0...126 (factory setting: 126).Remote addressing is possible.

Other functions

Sync and Freeze

Terminating resistors

Internally selectable with wire-hook switches.

Cable

According to EN 50 170, Vol. 2 (DIN 19 245T3).

Required accessories

Engineering Set PROFIBUS-DP, consisting of:

GSD file, Type file

w

PROFIBUS manual (9499-040-82911)

w

Function block(s) for Simatic S5/S7

w

Electromagnetic compatibility

Complies with EN 50 081-2 and EN 50 082-2.

Electrostatic discharge

Test to IEC 801-2,
8 kV air discharge
4 kV contact discharge

High-frequency interference

Test to ENV 50 140 (IEC 801-3)

80...1,000 MHz, 10 V/m
Effect: £ 1%

HF interference on leads

Test to ENV 50141 (IEC 801-6)

0.15...80 MHz, 10 V
Effect: £ 1%

Fast pulse trains (burst)

Test to IEC 801-4
2 kV applied to leads for supply voltage, and signal leads.

Effect: £ 5%resp. restart

High-energy single pulses (surge)

Test to IEC 801-5
1 kV symmetric or 2 kV asymmetric on leads for supply voltage.

0.5 kV symmetric or 1 kV asymmetric on signal leads.

I-17

Versions 9499-040-82711

I-4 Versions

The instrument version results from the combination of various
variants from the following table.

Fig. 2

Please mindfootnotes!
KS98-1 with screw terminals
only!

KS 98 Standard

KS

1

89

-

-

000

-

0

BASIC UNIT

POWER SUPPLY AND

CONTROL OUTPUTS

OPTION B

INTERFACE

OPTION

(standard)

OPTION

(modular)

SETTING

KS 98 with transmitter power supply
KS 98 with CANopen I/O

1)

90...250V, AC 4 relays
24V UC, 4 relays 1

90...250V AC 2 relays+ 2 mA/logic, 4
24V UC, 2 + 2 mA/logicrelays 5
no interface 0
TTL interface + di/do

RS422 + di/do + clock 2
PROFIBUS DP + di/do 3

no extensions

C

INP3, INP4, OUT3, di/do
Motherboard without modules

C

2)

Motherboard ordered modules inserted

Standard configuration
Customer-specific configuration

Operating instruction

3)

Standard (CE certification)

1
2

0

1

0
1
3

2)

4

0
9

0

0

I-18

APPROVALS

cULus approval

DIN EN 14597 certified

1)

Not possible with Modular Option C!
RM 200 not included in cULus approval !

2)

Not possible with CANopen ! I/O modules must be ordered separately!
Mind possible combinations and power limitations; Text!®

3)

Detailled system manual can be ordered separatelyor downloaded (www.pma-online.de)

U
D

9499-040-82711 Versions

)

I-4.1 I/O-Modules

Can be installed on instruments with modular option C basic card.

Fig. 3 Table of I/O-module Versions

9407 998 0 1

I-4.2

Singular order(separate delivery) 0

SOCKETS

Module group 1

In KS 98-1 pinned to socket 1
In KS 98-1 2pinned to socket
In KS 98-1 3pinned to socket

2Module group

In KS 98-1 4pinned to socket

3)

3)

3)

3)

1
2
3
4

R_INP: Pt100/1000, Ni100/1000, resistor 20

ANALOG INPUTS

TC_INP: Thermocouple, mV, 0/4...20mA 21
U_INP: -50...1500mV (z.B. Lambda-probe), 0...10V 22
U_OUT: Voltage output 30

ANALOG OUTPUTS

I_OUT: Current output

4)

31

DIDO: digitale in-/outputs 40

DIGITAL SIGNALS

3) Please note on your order: "mounted in KS in orderposition X"
4

Max. 1 current output module

F_INP: Frequency-/counter inputs 41

98-1

Ex-factory setting

All delivered units permit operation, parameter setting and configuration via the front-panel keys.

Instruments with default setting are delivered with a test engineering which permits testing of the basic instrument in ­puts and outputs (no I/O extension) without auxiliary means.

+

This engineering is not suitable for controlling a system. For this purpose, a customer-specific engineering is required
(see versions, section: Setting)

Instruments with "setting to specification" are delivered complete with an engineering. Code no. KS
98-1-1xx-xx09x-xxx is specified on the type label.

Accessories delivered with the instrument:

Operating manual, 4 fixing clamps

I-4.3 Auxiliary equipment

Engineering Tool ET/KS 98

Simulation SIM/KS 98-1

PC-Adapter

–

Adapter cable for connecting a PC (Engineering Tool) to the front-panel interface socket of the KS 98-1.

–

Updates and Demos on the PMA- Homepage (www.pma-online.de)

I/O-Modules I-19

Mounting 9499-040-82711

I-5 Mounting

96 96

?24

+0,8

92

1

160

2

3

1

KS 98-1advanced

4

1

2

3

92

4

+0,8

2

3

4

1...16

KS 98-1advanced

l

96

KS 98-1 advanced

96

max.

60°C

min. 0°C

max.

95% rel.

Fig. 4 Mounting

The instrument must be installed as described below. Required dimensions of the control cabinet cut-out and minimum
clearances for installation of further units are shown in the drawing.

For mounting, insert the unit into the control cabinet or cabinet door cut-out. Push the instrument module fully home
and mount it firmly by means of the locking screw. Four fixing clamps are delivered with the unit.

!

+

Fig. 5 Inserting the locking screws

Ü

These clamps have to be fitted in the instrument
from the control cabinet inside: 2 at top and bot

-

tom.

Ü

*

Now, the threaded pins of the fixing clamps can
be screwed against the control cabinet from insi

-

de.

¡

A rubber seal is fitted on the rear of the instrument front panel (in mounting direction).
This rubber seal must be in perfect condition, flush and cover the cut-out edges completely to ensure tightness!

cULus certification

For compliance with cUus certificate, the technical data at the beginning must be taken into account (see technical
data, page 12 .

I-20 Auxiliary equipment

9499-040-82711 Mounting

I-5.1 Function of wire-hook switches

For closing the wire-hook switches, release the locking screw, withdraw the instrument module from the housing and
close the wire-hook switch. Re-insert the instrument and lock it.

Ex-factory setting

S open
DP open - terminating resistor not active
CAN open - terminating resistor not active
TPS A 14/12

l

The unit contains electrostatically sensitive components. Comply with rules for protection against ESD during mounting.

Wire-hook switch S:

The switching status is signalled by function STATUS and can be used in the engineering for blocking e.g. operating
pages and other settings.

Wire-hook switch for PROFIBUS DP (Option B):

The bus terminating resistor can be connected by 2 wire-hook switches (DP) in KS98-1.Both wire-hook switches must
always be open or closed .

Wire-hook switch for CAN bus: (only Option CANbus):

Both ends of the CAN bus must be terminated (wire-hook switch closed).

Wire-hook switch for transmitter supply

Versions (KS98-11x-xxxxx) with transmitter supply are provided with a potential-free supply voltage for energization of
a 2-wire transmitter, or of max. 4 control inputs.

The output connections can be made to terminals A4(+) - A1(-) by means of 3 wire-hook switches.

If A14/A12 is used for di1/di2, A12 must be linked with A1.

Connectors Ü

14 (+) 12 (-) T open closed

4 (+) 1 (-) D closed open

*Ö

Remarks

Only available with INP1 configured for current or thermocouple
The voltage input of INP5 is then not available

Fig. 6 Position of wire-hook switches

View from below

TPS 3

View from above

CAN

*

Ü

TPS 1

TPS 2

TPS-card

*

Ü

Ö

Function of wire-hook switches I-21

Mounting 9499-040-82711

p

00201

R_Inp

8368

Energizing digital inputs (e.g. di1...di4)

_

+

1 (12)

2
3

A

*

di 1
di 2

4 (14)

B

di 3
di 4

1

3
4

Connection 2-wire-transducer (e.g. INP1)

+

tion)

(O

_

1 (12)

4 (14)

+

13

_

15

A

I-5.2 Retro-fitting and modific. of I/O-ext. (*watch connecting diagram)

Fig. 7 Mounting of i/o modules

*)

socket

-

43 2 1

l

Only for instruments with modular option C!

The instrument contains electrostatically sensitive
components. Original packing protects against elec
trostatic discharge (ESD), transport only in original
packing.

When mounting, rules for ESD protection must be

–

taken into account.

+

INP1

_

Connection:

KS 98-1 engineering must be taken into account, be­cause it determines pin allocation and signification of
connections.

Moreover, the rules for the performance limits must
be followed (see manual r 9499-040-82711).

Mounting

After releasing the locking screw, withdraw the KS
98-1 module from the housing.

Insert the module into the required socket with the

a

printed label pointing down-wards into the green
connector and click it in position in the small, white
contact b

at the top.

00201
R_Inp

The various modules can
be identified by the printed
label.
The last 5 digits of the
order number are given in
the upper line.

8368

I-5.3 I/O extension with CANopen

The unit offers a CANopen-compliant interface port for connection of the RM 200 system, KS 800 or additional KS 98-1
units with max. five CAN nodes. See installation notes in the CANopen system manual (9499-040-62411).

I-22 Retro-fitting and modific. of I/O-ext. (*watch connecting diagram)

9499-040-82711 Electrical connections - Safety hints

I-6 Electrical connections - Safety hints

a

a

a

Following the safety notes starting on page 6 is indispensable!

The installation must be provided with a switch or power circuit breaker which must be marked accordingly. The
switch must be located near the instrument and readily accessible for the operator.

When the instrument module is withdrawn from the housing, protection against dropping of conducting
parts into the open housing must be fitted.

The protective earth terminal (P3) must be connected to the cabinet ground. This applies also to 24V supply.

I-6.1 Electromagnetic compatibility

European guideline 89/336/EEC. The following European standards are met: EN 61326-1.

The unit can be installed in industrial areas (risk of radio interference in residential areas). A considerable increase of
the electromagnetic compatibility is possible by the following measures:

Installation of the unit in an earthed metal control cabinet.

w

Keeping power supply cables separate from signal and measurement cables.

w

Using twisted and screened measurement and signal cables (connect the screening to measurement earth).

w

Providing connected motor actuators with protective circuitry to manufacturer specifications. This measure pre-

w

vents high voltage peaks which may cause trouble for the instrument.

I-6.2 Measurement earth connection

+

Measurement earth connection is required for protection against interference. External interference voltages (incl. ra ­dio frequencies) may affect the perfect function of the device.

To ensure protection against interference, the measurement earth must be connected to cabinet ground.

Terminals A11(measurement earth) and P3 (protective earth) must be connected to cabinet ground via a short cable
(approx. 20 cm)! The protective earth conductor of the power supply cable must also be connected to this earth poten ­tial (cabinet ground). r See also diagram on page 24

Electromagnetic compatibility I-23

Electrical connections - Safety hints 9499-040-82711

I-6.3 RC protective circuitry

Load current free connections between the ground po
tentials must be realized so that they are suitable both
for the low-frequency range (safety of persons, etc.)
and the high-frequency range (good EMC values). The
connections must be made with low impedance.

All metal grounds of the components installed in the
cabinet Ü or in the cabinet door * must be scre
wed directly to the sheet-metal grounding plate to en
sure good and durable contact.

In particular, this applies to earthing rails ä, protecti
ve earth rail #, mountingplates for switching units

> and door earthing strips <.Controllers KS40/50/90
y and KS98-1 x are shown as an example for eart

hing.

The max. length of connections is 20 cm (see relevant
operating instructions).

Generally, the yellow/green protective earth is
too long to provide a high-quality ground
connection for high-frequency interferences.

Braided copper cables Ö provide a high frequency
conducting, low-resistance ground connection, especi­ally for connecting cabinet Ü and cabinet door *.

-

-

Fig. 8 Protective circuitry

ä
Ö

-

-

-

>

Ö

Ü

#

P3

A11

ä

*

x

6

y

<

Because of the skin effect, the surface rather than the cross section is decisive for low impedance. All connections
must have large surfaces and good contact. Any lacquer on the connecting surfaces must be removed.

!

Due to better HF properties, zinc-plated mounting plates and compartment walls are more suitable for large-surface
grounding than chromated mounting plates.

I-6.4 Galvanic isolations

Galvanically isolated connection groups are marked by lines in the connecting diagram.

Measuring and signal circuits: functional isolation up to a working voltage £ 33 VAC / 70 VDC against earth (to

w

DIN 61010-1; dashed lines).

Mains supply circuits 90...250 VAC, 24 VUC: safety isolation between circuits and against earth up to a working

w

voltage £ 300 Vr.m.s. (to EN 61010-1; full lines).

Instruments with I/O extension modules (KS98-1xx-x3xxx and KS98-1xx-x4xxx): sockets 1-2 and 3-4 are galvani

w

cally isolated from each other and from other signal inputs/outputs (functional isolation).

I-6.5 General connecting diagram

a
a

a

The max. permissible working voltage on input and signal circuits is 33 VAC / 70 VDC against earth ! Ot
herwise, the circuits must be isolated and marked with warning label for “contact hazard”.

The max. permissible working voltage on mains supply circuits may be 250 VAC against earth and against
each other ! Only on versions with transmitter power supply (factory setting: connection across terminals
A12-A14)

Additionally, the units must be protected by fuses for a max. power consumption of 12,3VA/7,1W per in
strument individually or in common (standard fuse ratings, min. 1A)!

-

-

-

I-24 RC protective circuitry

9499-040-82711 Electrical connections - Safety hints

Fig. 9 connecting diagram

OUT2

OUT1

INP4

INP3

OUT3

+

1

P

2
3
4

OUT5

5
6

7

OUT4

ßßß500VA, 250V, 2A

8
9

+

0/4...20mA

_

+

0/4...20mA

_

ßßß500VA, 250V, 2A

-

24 V

.

+

di 8 ( )

+

di 9 ( )

+

di 10 ( )

+

di 11 ( )

+

di 12 ( )

+

do 5
do 6

GND

+

0/4...20mA

_

+

0/4...20mA

_

+

0/4...20mA

_

Nur bei Geräten mit Transmitter-Speisung

1
1

For instruments with built-in transmitter power supply

1

Seulementpour les appareils avec alimentation transmetteur

For instruments with modular option C r see connecting diagram on page 28

10
11
12

13
14
15

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15

16

C

(Option)

A

oder

or/ou

10
11
12
13
14

1

15

16

B

(Option)

10
11
12
13
14
15
16

1
2
3
4
5
6

di (-)
di1 (+)
di2 (+)
+Volt
+mA

_

7
8
9

1

2
3
4
5
6
7
8
9

ABCP

1

1

INP5

Volt / mA

100%

_

0%

0/4...20mA

+

}}2

1

abcdef

-

24 V

+

+

di 3 ( )

+

di 4 ( )

+

di 5 ( )

+

di 6 ( )

+

di 7 ( )
do 1
do 2
do 3
do 4

RXD-B

GND

RXD-A

TXD-B

TXD-A

RS422 RS485 TTL PROFIBUS -DP

RGND

100 [

DATA B

DATA A

0%

+5V

GND

TRE

TXD

RXD

16

INP6

+

mA

_

100%

RxD/TxD-N

RxD/TxD-P

16

+

Volt

_

VP

GND

AB

OUT

IN

INTERBUS

INP1

a
a

General connecting diagram I-25

The protective earth must be connected also with 24 V DC / AC supply (see safety notes on page 23 ).
The polarity is uncritical.

Only on versions with transmitter power supply (factory setting: connection to terminals A12-A14).
Connection of the transmitter power supply is determined by the wire-hook switch r page 21.

Electrical connections - Safety hints 9499-040-82711

I-6.6 Analog inputs

Thermocouples

see general connecting diagram on page 25. No lead resistance adjustment.

Internal temperature compensation:

compensating lead up to the instrument terminals.
With AINP1, STK = int.CJC must be configured.

External temperature compensation:

Use separate cold junction reference with fixed reference temperature.

Compensating lead is used up to the cold junction reference. Copper lead between reference and instrument. With AINP1,
STK = ext.CJC and TKref = reference temperature must be configured.

Resistance thermometer

Pt 100 in 3-wire connection.
Lead resistance adjustment is not necessary, if RL1 is equal

RL2.

Resistance thermometer

Pt 100 in 2-wire connection. Lead resistance adjustment is
necessary: Ra must be equal to RL1 + RL2.

Two Resistance thermometer

Pt100 for difference. Lead resistance compensation: proceed
as described in chapter calibration page 27 - I-9.4.

Resistance transducer

Measurement calibration r proceed as described in chapter
calibration page 27 - I-9.4.

16

15

RL1

}

16

RL1

Ra = RL1+RL2

16 15

RL1

15

}1 }2

RL1 = RL2

RL2

Ra

RL2

}

xeff = 1 - 2}}

RL2

14

14

14

Standard current signals 0/4...20 mA

Input resistance: 50 [, configure scaling and digits behind the decimal point.

Standard voltage signals 0/2...10V

Input resistance: ? 100 k[
(Voltage input module U_INP: >1 G[),
configure scaling and digits behind the decimal point.

+

a

I-26 Analog inputs

INP5 is a difference input, the reference potential of which is connected to terminal A9. With voltage input, A6 must
always be connected to A9.

The inputs INP1 / INP6 are interconnected (common reference potential). This must be taken into account if both
inputs must be used for standard current signal. If necessary, galvanic isolation should be applied.

9499-040-82711 Electrical connections - Safety hints

I-6.7 Digital in- and outputs

The digital inputs and outputs must be energized from one or several external 24 V DC sources. Power consumption is
5 mA per input. The max. load is 70 m A per output.

Examples:

Digital inputs (connector A)

A

()()-

24V (ext.)

+

Imax. 5 mA
Imax. 5 mA

Digital inputs and outputs at one voltage source (e.g. connector B) 70mA!

di 1
di 2

1
2
3

B

()()-

1

24V (ext.1)

+

Imax. 5 mA
Imax. 5 mA
Imax. 5 mA
Imax. 5 mA
Imax. 5 mA

di 3
di 4
di 5
di 6
di 7

10
11

2
3
4
5
6

Imax. 0,1 A

Imax. 0,1 ARLImax. 0,1 A

Imax. 0,1 A

7

do 1

8

do 2

9

do 3
do 4

Digital inputs and outputs at two voltage sources (e.g. connector B)

B

()()-

24V

(ext.1)

+

Imax. 6 mA
Imax. 6 mA
Imax. 6 mA
Imax. 6 mA
Imax. 6 mA

di 3
di 4
di 5
di 6
di 7

10
11

1

()()-

24V
2
3

(ext.2)

+

4
5
6
7
8
9

do 1
do 2
do 3
do 4

Imax. 70 m A

Imax. 70 m ARLImax. 70 m A

Imax. 70 m A

Digital in- and outputs I-27

Electrical connections - Safety hints 9499-040-82711

I-6.8 Connecting diagram i/o-modules

(Modular Option C)

+

CAN and modular option C are mutually precluding.

The inputs and outputs of multi-function unit KS98-1 can be adapted to the individual application by means of “modu
lar optionC". The supporting card is firmly installed in the unit.

The card contains four sockets for various I/O modules which can be combined, whereby the positions of the various
connection types are dependent on engineering.

The KS98-1 programming personnel must provide a connecting diagram corresponding to the block diagram ( r page )
for installation of the device.

4-wire 3-wire 2-wire Poti

R1

R1

R1

Resistive input
(9407-998-0x201)

TC, mV, mA / V inputs

(9407-998-0x211) /

(9407-998-0x221)

R1

R2

+
_

I1

I2

U1

+
_

U2

R2

+

_

+

_

+

}1

+

}2

-

I1

I2

di 1 (+)
di 2 (+)

di 1/2 (-)

di 1 (+)
di 2 (+)

di 1/2 (-)

+
_

+
_

di 1 (+)
di 2 (+)

di 1/2 (-)

di 1 (+)
di 2 (+)

di 1/2 (-)

do1/2(+)

di 1 (+)
di 2 (+)

di 1/2 (-)

U1

U2

do 1
do 2

do 1/2 (-)

+

_

+

_

Fig. 10 Quadruple counter up/down counter 2 x counter and2xfrequency

Voltage / current outputs

V

(9407-998-0x301) /

V

(9407-998-0x311)

Combined digital inputs/ outputs

(9407-998-0x401)

Frequency/ Counter inputs

(9407-998-0x241)

I-28 Connecting diagram i/o-modules

9499-040-82711 Commissioning

I-7 Commissioning

Before switching on the instrument, ensure that the following points are taken into account:

The supply voltage must correspond to the specification on the type label!

w

All covers required for contact protection must be fitted.

w

Before operation start, check that other equipment in the same signal loop is not affected. If necessary, appropri

w

ate measures must be taken.

-

a

a

The unit is freely configurable. For this reason, the input and output behaviour is determined by the loaded engi

w

neering. Before commissioning, make sure that the right instructions for system and instrument commissioning
are available.

Unless an application-specific engineering was loaded, the unit is equipped with the IO test engineering described on
page 49.

Before instrument switch-on, the plant-specific input and output signal types must be adjusted on the in
strument, in order to avoid damage to the plant and to the device.

On instruments without default setting, partial I/O signal testing is possible.

The effect on connected equipment must be taken into account.

After supply voltage switch-on, start-up logo and Main menu wait! are displayed, followed by display of the main
menu during several seconds .

Unless a selection is made during this time, the first operating page (e.g. a controller) is displayed automatically, wit ­hout marking a line or a field.

-

-

Connecting diagram i/o-modules I-29

Operation 9499-040-82711

Ü¡ ¢£¤

I-8 Operation

The operation of the device is menu-guided. The menu is divided into several levels which can all be influenced via the
engineering, i.e. the final scope of the menu is dependent on the engineering.

This manual describes the operating functions which are independent of the engineering.

I-8.1 Front view

LEDs (Ü¡¢£):

for indication of conditions determined by the engineering,
e.g. alarms or switching states.

HDIM keys (|–©¨):

Operation is by four keys for selection of pages and input on
pages.

DI

The two functions of keys up/down are:

Navigation in menus and on pages

–

Changing input values (e.g. )

–

M

The two significations of the selector key are dependent on
the selected field:

– Pressing the selector key (confirmation / Enter): startspage changing,
– starts value alteration via the up/down keys and confirms the adjustment subsequently ( r page 32).

H

The functions of the auto/manual key are dependent on operating page, i.e. this key is sometimes called function key.

– Controller: auto/manual switchover
–

Programmer: programmer control

–

Adjustment of digital values.

Fig. 11

¥|

–

©

y

x

#

Locking screw:

for locking the instrument module in the housing

<

PC interface:

PC interface for engineering tool ET/KS98 and BlueControl. The tools permit structuring/soft-wiring/configurati
on/parameter setting/operation.

y

Display/operating page:

–

LCD point matrix (160 x 80 dots),

–

changeable green/red back lighting, direct/inverse display mode.

Display is dependent on configured functions.

I-30 Front view

-