West Control Solutions Pro-4 User Manual

West Pro-4 user manual – 59559

û

BlueControl

More efficiency in engineering,

more overview in operating:

The projecting environment for the BluePort



controllers

Description of symbols:

g General information
a General warning
l Attention: ESD sensitive devices

© PMA Prozeß- und Maschinen-Automation GmbH • Printed in Germany

All rights reserved. No part of this document may bereproduced or published in any form

or by any means without prior written permission from the copyright owner.

A publication of PMA Prozeß- und Maschinen Automation

P.O.Box 310229

D-34058 Kassel

Germany

Contents

1 Mounting ..............................5

2 Electrical connections .......................6

2.1 Connecting diagram .......................6

2.2 Terminal connection.........................7

3 Operation .............................11

3.1 Front view ............................11

3.2 Behaviour after power-on .....................12

3.3 Operating level ...........................12

3.4 Error list / Maintenance manager .................13

3.5 Self-tuning .............................16

3.5.1 Preparation for self-tuning .......................16

3.5.2 Optimization after start-up or at the set-point ..............17

3.5.3 Selecting the method ( ConF/ Cntr/ tunE).............17

3.5.4 Step attempt after start-up ......................18

3.5.5 Pulse attempt after start-up .......................18

3.5.6 Optimization at the set-point ......................18

3.5.7 Optimization at the set-point for 3-point stepping controller ......20

3.5.8 Self-tuning start .............................21

3.5.9 Self-tuning cancellation ........................21

3.5.10 Acknowledgement procedures in case of unsuccessful self-tuning . 22

3.5.11 Examples for self-tuning attempts ..................23

3.6 Manual self-tuning .........................24

3.7 Second PID parameter set .....................25

3.8 Alarm handling...........................26

3.9 Operating structure.........................28

4 Configuration level ........................29

4.1 Configuration survey ....................29

4.2 Configuration parameters ....................30

4.3 Set-point processing ........................43

4.3.1 Set-point gradient / ramp ........................43

4.4 Switching behaviuor ........................44

4.4.1 Standard ( CyCl= 0 ) .........................44

4.4.2 Switching attitude linear ( CyCl= 1 ).................44

KS 90-1 / KS 92-1 3

4.4.3 Switching attitude non-linear ( CyCl= 2 )...............45

4.4.4 Heating and cooling with constant period ( CyCl= 3 )........46

4.5 Configuration examples ......................47

4.5.1 On-Off controller / Signaller (inverse) .................47

4.5.2 2-point controller (inverse) .......................48

4.5.3 3-point controller (relay & relay) ....................49

4.5.4 3-point stepping controller (relay & relay) ...............50

4.5.5 Continuous controller (inverse) .....................51

4.5.6 ∆ - Y - Off controller / 2-point controller with pre-contact ......52

4.5.7 Continuous controller with position controller .............53

4.5.8 Measured value output .........................54

5 Parameter setting level ......................55

5.1 Parameter survey ........................55

5.2 Parameters .............................56

5.3 Input scaling ............................59

5.3.1 Input Inp.1 and InP.3 .............60

5.3.2 Input InP.2...............................60

6 Calibration level .........................61

7 Special functions .........................64

7.1 DAC®– motor actuator monitoring ...............64

7.2 O2measurement ..........................66

7.2.1 Connection ...............................66

7.2.2 Configuration: ..............................67

7.3 Linearization ............................68

7.4 Loop alarm .............................69

7.5 Heating current input / heating current alarm ...........69

7.6 KS90-1 as Modbus master .....................70

7.7 Back-up controller (PROFIBUS) .................70

8 BlueControl ............................71

9 Versions ..............................72

10 Technical data ..........................73

11 Safety hints ............................77

11.1 Resetting to factory setting, ....................78

4 KS 90-1 / KS 92-1

1 Mounting

9

min.48 (1.89")

92

Mounting

+0,8

10

(3.78")

96

48 (1.89")

max.

(0.4")

118

1199

1199

°C

°C

°F

°F

para

para

func

func

Ada

Ada

Err

Err

F

F

è

KS 92-1 advanced

KS 90-1

60°C

0°Cmin.

(4.65")

123

1234

1200

1200

SP.E

SP.2

SP.E

SP.2

advanced

+0.03

+0,8

1..10

92

(0.04..0.4")

4

(3.62" )

2

1

3

4

+0,8

2

920.1

+0,6

45

(1.77" )

+0.02

Loc

security switch

Ü

or:

96

para
func

Ada

Err

F

KS 92-1 advanced

o

C

921.2

run

SP.E

SP.2

run

SP.E

SP.2

96

118

10

max.
95% rel.

l

Ü

%

*

*

Safety switch:

For access to the safety switch, the controller must be withdrawn from the hou
sing. Squeeze the top and bottom of the front bezel between thumb and forefinger
and pull the controller firmly from the housing.

Loc open Access to the levels is as adjusted by means of BlueControl (engineering tool) 2

closed 1 all levels accessible wihout restriction

1 Factory setting 2 Default setting: display of all levels

suppressed, password PASS = OFF

Caution! The unit contains ESD-sensitive components.

-

KS 90-1 / KS 92-1 5

Electrical connections

6

2 Electrical connections

2.1 Connecting diagram

3

1

2

90...250V
24VUC

OUT1

OUT2

OUT3

KS90-1. -4 ...
KS90-1. -5 ...

OUT4

KS90-1. -25...

!

V

V

d
b

c

e

8

9

0

RGND

DATA B

DATA A

RS485 RS422

Modbus RTU

1
2
3

4
5
6

7
8
9

10
11
12

13
14
15

a

+24V DC

OUT5
OUT6

24V GND

RXD-B

RXD-A

TXD-B

TXD-A

GND

di2

di3

U

1
2
3

di1

7

di2

4
5
6

7

g

HC

mA

INP2

f

5

8
9

10
11

(mV)

0%

100%

mA

INP3

KS90-1..-.1...

12
13

14
15

mA

Volt

INP1

4

(16)

Option

1

(2)

3

4

5

10

11

12

13

14

15

(16)

17

6

7

8

9

VP (5V)

DGND

RxD/TxD-N

RxD/TxD-P

Schirm/
Screen

T

17

PROFIBUS-DP

(mV)

a

b

390 [

220 [

Adapter

390 [

cd

DGND

9

8

7

VP (5V)

6

Profibus DP

e

max.

1200m

5

4

3

2

1

5

9

4

8

3

7

2

6

1

g

Dependent of order, the controller is fitted with :

flat-pin terminals 1 x 6,3mm or 2 x 2,8mm to DIN 46 244 or

w

screw terminals for 0,5 to 2,5mm²

w

On instruments with screw terminals, the insulation must be stripped by min.
12 mm. Choose end crimps accordingly!

Connecting diagram 6 KS 90-1 / KS 92-1

2.2 Terminal connection

Power supply connection 1

See chapter "Technical data"

Electrical connections

Connection of outputs OUT1/2 2

2 OUT1/2 heating/cooling

Relay outputs (250V/2A), potential-free
changeover contact

L

Connection of outputs OUT3/4 3

a relay (250V/2A), potential-free

changeover contact

universal output

b current (0/4...20mA)
c voltage (0/2...10V)
d transmitter supply
e logic (0..20mA / 0..12V)

Connection of input INP1 4

N

Input mostly used for variable x1 (pro­cess value)

a thermocouple
b resistance thermometer (Pt100/ Pt1000/ KTY/ ...)
c current (0/4...20mA)
d voltage (0/2...10V)

1

2

3

4

5

6

7

8

9

10
11
12

13
14
15

10
11
12

13
14

(16)

1
2
3

4
5
6
7
8
9

15

17

+

Connection of input INP2 5

f heating current input (0..50mA AC)

or input for ext. set-point (0/4...20mA)
g potentiometer input for position
feedback

Connection of input INP2 5

a Heating current input (0...50mA AC)

or input for ext. Set-point (0/4...20mA)
b Potentiometer input for position

feedback

Connection of input INP3 6

As input INP1, but without voltage

Connection of inputs di1, di2 7

Digital input, configurable as switch or
push-button

5 INP2 current tansformer

L

1
2

3
4

5
6

7
8

N

Logik

9

10
11
12

13
14
15

10
11
12

13
14
15

(16)

17

1
2
3

4
5

6
7

8
9

SSR

_

+

KS 90-1 / KS 92-1 7 Terminal connection

Electrical connections

Connection of inputs di2/3 8 (option)

Digital inputs (24VDC external), galvanically isolated, configurable as switch or
push-button

Connection of output U

9 (option)

T

Supply voltage connection for external energization

Connection of outputs OUT5/6 0 (option)

Digital outputs (opto-coupler), galvanic isolated, common positive control volta
ge, output rating: 18...32VDC

Connection of bus interface ! (option)

PROFIBUS DP or RS422/485 interface with Modbus RTU protocol

89 di2/3, 2-wire transmitter supply

OUT3

J

10
11

12

13
14
15

Option

15

(16)

17

13
14

-

+

-

g

+24VDC

3

0V

+

1

2

-

17,5V
22mA

K

5mA

5mA

+

-

1

(2)

3

4

5

6

7

8

9

10

11

12

13

14

15

(16)

17

J

Analog outputs OUT3 or OUT4 and transmitter supply UTare connected to
different voltage potentials. Therefore, take care not to make an external galvanic
connection between OUT3/4 and U

with analog outputs!

T

Terminal connection 8 KS 90-1 / KS 92-1

3 OUT3 transmitter supply

Electrical connections

3

13V

22mA

1

K

2

-

+

10
11

12

13
14
15

11
12

15

(16)

17

13
14

+

-

9 RS485 interface (with RS232-RS485 interface converter) *

R = 120...200 OhmT

RT

RGND connection optional

RGND

DATA B

DATA A

option

1

(2)

3

4

5

6

7

8

9

10

11

12

13

14

15

(16)

17

J

10

11

12

13

14

15

RGND

DATA B

DATA A

option

1

(2)

3

4

5

6

7

8

9

10

11

12

13

14

15

(16)

17

10

11

12

13

14

15

max. 1000m

"Twisted Pair” cable

RGND

DATA B

DATA A

R=100 Ohm

option

1

(2)

3

4

5

6

7

8

9

10

11

12

13

14

15

(16)

17

RT

R = 120...200 OhmT

10

11

12

13

14

15

PC

RS485-RS232

converter

* Interface description Modbus RTU in speperate manual: see page 71.

KS 90-1 / KS 92-1 9 Terminal connection

Electrical connections

3 OUT3 as logic output with solid-state relay (series and parallel connection)

Series connection

SSR

I =22mA

max

_

4V

+

SSR

_

4V

+

SSR

_

4V

+

12V

10
11

12

Logic

SSR

SSR

Parallel connection

I =22mA

max

_

12V

+

_

+

10
11

12

KS90-1 connecting example:

L1

L2

Fuse

1
2

3
4

5
6

7
8
9

10
11

12

13
14
15

KS90-1

Logik

10
11
12

13
14

(16)

1
2
3

4
5
6
7
8
9

SSR

_

+

15

17

Contactor

+

Fuse

Heating

1 TB 40-1 Temperaturelimiter

Standard-version (3 Relays):
TB40-100-0000D-000

further versions on requestr

1

2

3

4

1

TB 40-1

Temperaturelimiter

5

6

7

8

9

10

11

12

13

14

15

+

Reset­key

Fuse

N1

N2

a

CAUTION: Using a temperature limiter is recommendable in systems where
overtemperature implies a fire hazard or other risks.

Terminal connection 10 KS 90-1 / KS 92-1

3 Operation

1 2 3

4

F

SP.E

SP.2

920.1

921.2

C

para

func

Ada

Err

SP.E

SP.2

o

1200

1199

°C
°F

SP.2

SP.E

para
func

Ada

Err

F

123

4

1

2

3

4

5
6

$

7
8

%

&

(

/

p

9

0

SP

§"

!

92

4

C

9

0

!

§"

7
8

$

%

&

/

(

5
6

1

2

3

3.1 Front view

Operation

1 Statuses of switching outputs OuT.1... 6 2 Process value display
3 Setpoint or correcting variable display 4 °C or °F display signalling
5 Signals ConF- and PArA level 6 Signals activated function key
7 Selft-tuning active 8 Entry into the error list
9 Bargraph or plain text display 0 Setpoint SP.2 is effective
! Setpoint SP.E is effective " Setpoint gradient is effective

§ Manual-automatic switchover: Off: automatic On: manual mode (adjustment possible)
Blinks: manual mode (adjustment not possible (r ConF/ Cntr/ MAn))

$ Enter key: call up extented operating level / error list
% Up/ down keys: changing setpoint or correcting variable
& automatic/manual or other functions ( r ConF /LOGI)
/ freely configurable function key with pure controller operation
( PC connection for BlueControl (engineering tool)

g

LED colours: LED 1, 2, 3, 4: yellow, Bargraph: red, other LEDs: red

In the upper display line, the process value is always displayed. At parameter,
configuration, calibration as well as extended operating level, the bottom display
line changes cyclically between parameter name and parameter value.

KS 90-1 / KS 92-1 11 Front view

Operation

A

M

l

3.2 Behaviour after power-on

After supply voltage switch-on, the unit starts with the operating level.
The unit is in the condition which was active before power-off.
If the controller was in manual mode at supply voltage switch-off, the controller
will re-start with the last output value in manual mode at power-on.

3.3 Operating level

The content of the extended operating level is determined by means of BlueCon
trol (engineering tool). Parameters which are used frequently or the display of
which is important can be copied to the extended operating level.

time

out

utomatic

1199

1200

È
Ì

Ù

1199

Y21

i

Ò

Ò

i

anua

1199

Y21

È
Ì

Ù

1199

1200

time

out

-

È

Ù

only

display

Ù

Ì

Extended operating level

time

out

Error list (if error exists)

126

FbF.1

Err

Display

switching

126

2

Err

Behaviour after power-on 12 KS 90-1 / KS 92-1

3.4 Error list / Maintenance manager

Operation

With one or several errors, the extended operating level al

­ways starts with the error list. Signalling an actual entry in
the error list (alarm, error) is done by the Err LED in the
display. To reach the error list press Ù twice.

Err LED status Signification Proceed as follows

blinks

(status 2)

lit

(status 1)

off

(status 0)

Alarm due to existing
error

Error removed, alarm
not acknowledged

No error, all alarm
entries deleted

Determine the error type in the error list

­After error correction the unit changes to status 1

­Acknowledge the alarm in the error list pressing key ÈorÌ

­The alarm entry was deleted (status 0).

-

-Not visible except when acknowledging

-

Error list:

Name

E.1

E.2

E.3

E.4

FbF.1

Sht.1

POL.1
FbF.2

Sht.2

POL.2
FbF.3

Sht.3

POL.3

Description Cause Possible remedial action

Internal error,
cannot be removed

Internal error, can be
reset

- E.g. defective EEPROM - Contact PMA service

- Return unit to our factory

- e.g. EMC trouble - Keep measurement and power supply
cables in separate runs

- Ensure that interference suppression
of contactors is provided

Configuration error,
can be reset

- wrong configuration

- missing configuration

Hardware error - Codenumber and

hardware are not
identical

Sensor break INP1

-

Sensor defective

-

Faulty cabling

Short circuit INP1-Sensor defective

-

Faulty cabling

INP1polarity error

-

Faulty cabling

Sensor break INP2-Sensor defective

-

Faulty cabling

Short circuit INP2-Sensor defective

-

Faulty cabling

INP2 polarity

-

Faulty cabling

Sensor break INP3-Sensor defective

-

Faulty cabling

Short circuit INP3-Sensor defective

-

Faulty cabling

INP3 polarity

-

Faulty cabling

- Check interaction of configuration /
parameters

- Contact PMA service

- Elektronic-/Optioncard must be
exchanged

-

Replace INP1 sensor

-

Check INP1 connection

-

Replace INP1 sensor

-

Check INP1 connection

-

Reverse INP1 polarity

-

Replace INP2 sensor

-

Check INP2 connection

-

Replace sensor INP2

-

Check INP2 connection

-

Reverse INP2 polarity

-

Replace INP3 sensor

-

Check INP3 connection

-

Replace sensor INP3

-

Check INP3 connection

-

Reverse INP3 polarity

1199

°C

°F

1200

para
func

Ada

Err

SP.E

SP.2

KS 90-1 / KS 92-1 13 Error list / Maintenance manager

Operation

Name

HCA

SSr

LooP

AdA.H

AdA.C

LiM.1

Lim.2

Lim.3

Inf.1

Inf.2

E.5

dp.1

dp.2

dp.3

Description Cause Possible remedial action

Heating current
alarm (HCA)

Heating current circuit

­interrupted, I< HC.A or

Check heating current circuit

­If necessary, replace heater band

-

I> HC.A (dependent of
configuration)
Heater band defective

-

Heating current
short circuit (SSR)

Current flow in heating

­circuit with controller

Check heating current circuit

­If necessary, replace solid-state relay

-

off
SSR defective

-

Control loop alarm
(LOOP)

Input signal defective or

­not connected correctly
Output not connected

­correctly

Check heating or cooling circuit

­Check sensor and replace it, if

­necessary
Check controller and switching

­device

Self-tuning heating
alarm

See Self-tuning heating

­error status

see Self-tuning heating error status

-

(ADAH)
Self-tuning heating

alarm cooling
(ADAC)

stored limit alarm 1 - adjusted limit value 1

See Self-tuning cooling

­error status

see Self-tuning cooling error status

-

- check process

exceeded

stored limit alarm 2 - adjusted limit value 2

- check process

exceeded

stored limit alarm 3 - adjusted limit value 3

- check process

exceeded

time limit value
message

duty cycle message
(digital ouputs)

Internal error in DP
module

- adjusted number of
operating hours reached

- adjusted number of duty
cycles reached

-

self-test error

-

internal communication

- application-specific

- application-specific

-

Switch on the instrument again

-

Contact PMA service

interrupted

No access by bus
master

-

bus error

-

connector problem

-

no bus connection

Faulty configuration-Faulty DP

configuration telegram

Inadmissible
parameter setting
telegram sent

-

Faulty DP parameter
setting telegram

-

Check cable

-

Check connector

-

Check connections

-

Check DP configuration telegram in
master

-

Check DP parameter setting
telegram in master

No data

dp.4

Error list / Maintenance manager 14 KS 90-1 / KS 92-1

communication

-

Bus error

-

Address error

-

Master stopped

-

Check cable connection

-

Check address

-

Check master setting

Operation

g

g

Saved alarms (Err-LED is lit) can be acknowledged and deleted with the digital
input di1/2/3, the è-key or the Ò-key.
Configuration, see page 37: ConF / LOGI / Err.r

If an alarm is still valid that means the cause of the alarm is not removed so far
(Err-LED blinks), then other saved alarms can not be acknowledged and deleted.

Self-tuning heating ( ADA.H) and cooling ( ADA.C) error status:

Error

status

Description Behaviour

0

No error

3

Faulty control action Re-configure controller (inverse i direct)

4

No response of process
variable

5

Low reversal point Increase ( ADA.H) max. output limiting Y.Hi or decrease (

The control loop is perhaps not closed: check sensor, connections
and process

ADA.C) min. output limiting Y.Lo

6

Danger of exceeded

If necessary, increase (inverse) or reduce (direct) set-point
set-point (parameter
determined)

7

Output step change
too small (dy > 5%)

8

Set-point reserve too
small

Increase ( ADA.H) max. output limiting Y.Hi or reduce (

ADA.C) min. output limiting Y.Lo

Acknowledgment of this error message leads to switch-over to

automatic mode.If self-tuning shall be continued,

increase set-point (invers), reduce set-point (direct)

or decrease set-point range

(r PArA / SEtp / SP.LO and SP.Hi )

9

Impulse tuning failed The control loop is perhaps not closed: check sensor, connections

and process

DAC function ( DAC) error status:

Error status

0
3
4
5
6

KS 90-1 / KS 92-1 15 Error list / Maintenance manager

No error
Output is blocked Check the drive for blockage
Wrong method of operation Wrong phasing, defect motor capacitor
Fail at Yp measurement Check the connection to the Yp input
Calibration error Manual calibration necessary

Description Behaviour

Operation

3.5 Self-tuning

For determination of optimum process parameters, self-tuning is possible.

After starting by the operator, the controller makes an adaptation attempt, where
by the process characteristics are used to calculate the parameters for fast line-out
to the set-point without overshoot.

The following parameters are optimized when self-tuning:
Parameter set 1:

Pb1 - Proportional band 1 (heating) in engineering units [e.g. °C]
ti1 - Integral time 1 (heating) in [s]r only, unless set to OFF
td1 - Derivative time 1 (heating) in [s]r only, unless set to OFF
t1 - Minimum cycle time 1 (heating) in [s]r only, unless Adt0 was

set to “no self-tuning” during configuration by means of
BlueControl

®

.

Pb2 - Proportional band 2 (cooling) in engineering units [e.g. °C]
ti2 - Integral time 2 (cooling) in [s]r only, unless set to OFF
td2 - Derivative time 2 (cooling) in [s]r only, unless set to OFF
t2 - Minimum cycle time 2 (cooling) in [s] r only, unless Adt0

was set to “no self-tuning” during configuration by means of
BlueControl

®

.

-

Parameter set 2: analogous to parameter set 1 (see page 25)

3.5.1 Preparation for self-tuning

Adjust the controller measuring range as control range limits. Set values

w

rnG.L and rnG.H to the limits of subsequent control.
(ConfigurationrControllerrlower and upper control range limits)
ConFrCntrr rnG.L and rnG.H

Determine which parameter set shall be optimized.

w

-The instantaneously effective parameter set is optimized.
r Activate the relevant parameter set (1 or 2).

Determine which parameter set shall be optimized (see tables above).

w

Select the self-tuning method

w

see chapter 3.5.3

-Step attempt after start-up

-Pulse attempt after start-up

-Optimization at the set-point

Self-tuning 16 KS 90-1 / KS 92-1

3.5.2 Optimization after start-up or at the set-point

The two methods are optimization after start-up and at the set-point.
As control parameters are always optimal only for a limited process range, vari
ous methods can be selected dependent of requirements. If the process behaviour
is very different after start-up and directly at the set-point, parameter sets 1 and 2
can be optimized using different methods. Switch-over between parameter sets
dependent of process status is possible (see page ).

Optimization after start-up: (see page 4)
Optimization after start-up requires a certain separation between process value
and set-point. This separation enables the controller to determine the control pa
rameters by evaluation of the process when lining out to the set-point.
This method optimizes the control loop from the start conditions to the set-point,
whereby a wide control range is covered.
We recommend selecting optimization method “Step attempt after start-up”
with tunE = 0 first. Unless this attempt is completed successfully, we recom
mend a “Pulse attempt after start-up”.

Operation

-

-

-

Optimization at the set-point: (see page 18)
For optimizing at the set-point, the controller outputs a disturbance variable to the
process. This is done by changing the output variable shortly. The process value
changed by this pulse is evaluated. The detected process parameters are conver­ted into control parameters and saved in the controller.
This procedure optimizes the control loop directly at the set-point. The advantage
is in the small control deviation during optimization.

3.5.3 Selecting the method ( ConF/ Cntr/ tunE)

Selection criteria for the optimization method:

Step attempt after start-up Pulse attempt after start-up Optimization at the set-point

tunE =0
tunE =1
tunE =2

sufficient set-point reserve is

provided

sufficient set-point reserve is

provided

always step attempt after

start-up

Sufficient set-point reserve:

inverse controller:(with process value < set-point- (10% of rnGH - rnGL)
direct controller: (with process value > set-point + (10% of rnGH - rnGL)

sufficient set-point reserve is not

provided

sufficient set-point reserve is not

provided

KS 90-1 / KS 92-1 17 Self-tuning

Operation

3.5.4 Step attempt after start-up

Condition: - tunE = 0 and sufficient set-point reserve provided
or - tunE =2

The controller outputs 0% correcting variable or Y.Lo and waits, until the process
is at rest (see start-conditions on page 8).
Subsequently, a correcting variable step change to 100% is output.
The controller attempts to calculate the optimum control parameters from the pro
cess response. If this is done successfully, the optimized parameters are taken
over and used for line-out to the set-point.

With a 3-point controller, this is followed by “cooling”.
After completing the 1st step as described, a correcting variable of -100% (100%
cooling energy) is output from the set-point. After successfull determination of
the “cooling parameters”, line-out to the set-point is using the optimized parame
ters.

-

-

3.5.5 Pulse attempt after start-up

Condition: - tunE = 1 and sufficient set-point reserve provided.
The controller outputs 0% correcting variable or Y.Lo and waits, until the process

is at rest (see start conditions page 8)
Subsequently, a short pulse of 100% is output (Y=100%) and reset.
The controller attempts to determine the optimum control parameters from the
process response. If this is completed successfully, these optimized parameters
are taken over and used for line-out to the set-point.

With a 3-point controller, this is followed by “cooling”.

After completing the 1st step as described and line-out to the set-point, correcting
variable "heating" remains unchanged and a cooling pulse (100% cooling energy)
is output additionally. After successful determination of the “cooling parame
ters”, the optimized parameters are used for line-out to the set-point.

3.5.6 Optimization at the set-point

Conditions:

A sufficient set-point reserve is not provided at self-tuning start (see page 17).

w

tunE is0or1

w

With Strt = 1 configured and detection of a process value oscillation by

w

more than ± 0,5% of (rnG.H - rnG.L) by the controller, the control
parameters are preset for process stabilization and the controller realizes an
optimization at the set-point (see figure “Optimization at the set-point”).
when the step attempt after power-on has failed

w

with active gradient function ( PArA/ SETP/ r.SP≠ OFF), the set-point

w

gradient is started from the process value and there isn't a sufficient set-point
reserve.

-

Self-tuning 18 KS 90-1 / KS 92-1

Operation

Optimization-at-the-set-point procedure:

The controller uses its instantaneous parameters for control to the set-point. In li
ned out condition, the controller makes a pulse attempt. This pulse reduces the
correcting variable by max. 20% 1, to generate a slight process value unders
hoot. The changing process is analyzed and the parameters thus calculated are re
corded in the controller. The optimized parameters are used for line-out to
theset-point.

Optimization at the set-point

-

set-point

process value

-

-

correcting
variable

With a 3-point controller, optimization for the “heating“ or “cooling” parameters
occurs dependent of the instantaneous condition.
These two optimizations must be started separately.

1 If the correcting variable is too low for reduction in lined out condition it is
increased by max. 20%.

KS 90-1 / KS 92-1 19 Self-tuning

Operation

3.5.7 Optimization at the set-point for 3-point stepping controller

With 3-point stepping controllers, the pulse attempt can be made with or without
position feedback. Unless feedback is provided, the controller calculates the mo
tor actuator position internally by varying an integrator with the adjusted actuator
travel time. For this reason, precise entry of the actuator travel time (tt), as time
between stops is highly important. Due to position simulation, the controller
knows whether an increased or reduced pulse must be output. After supply volta
ge switch-on, position simulation is at 50%. When the motor actuator was varied
by the adjusted travel time in one go, internal calculation occurs, i.e. the position
corresponds to the simulation:

Simulation actual position

-

-

Internal calculation

tt

Internal calculation always occurs, when the actuator was varied by travel time

tt in one go

, independent of manual or automatic mode. When interrupting the
variation, internal calculation is cancelled. Unless internal calculation occurred
already after self-tuning start, it will occur automatically by closing the actuator
once.

Unless the positioning limits were reached within 10 hours, a significant deviati

­on between simulation and actual position may have occurred. In this case, the
controller would realize minor internal calculation, i.e. the actuator would be clo

­sed by 20 %, and re-opened by 20 % subsequently. As a result, the controller
knows that there is a 20% reserve for the attempt.

Self-tuning 20 KS 90-1 / KS 92-1

3.5.8 Self-tuning start

Start condition:

For process evaluation, a stable condition is required. Therefore, the

w

controller waits until the process has reached a stable condition after
self-tuning start.
The rest condition is considered being reached, when the process value

oscillation is smaller than ± 0,5% of (rnG.H - rnG.L).
For self-tuning start after start-up, a 10% difference from (SP.LO ... SP.Hi)

w

is required.

Operation

g

Self-tuning start can be blocked via BlueControl®(engineering tool) ( P.Loc).

Strt = 0 Only manual start by pressing keys Ù and È

simultaneously or via interface is possible.

Strt = 1 Manual start by press keys Ù and È simultaneously

via interface and automatic start after power-on and detection
of process oscillations.

Ada LED status Signification

blinks Waiting, until process

calms down

lit Self-tuning is running

off Self-tuning not activ

or ended

3.5.9 Self-tuning cancellation

By the operator:

Self-tuning can always be cancelled by the operator. For this, press Ù and È
key simultaneously.With controller switch-over to manual mode after self-tuning
start, self-tuning is cancelled. When self-tuning is cancelled, the controller will
continue operating using the old parameter values.

1199

°C

°F

1200

para
func

Ada

Err

SP.E

SP.2

By the controller:

If the Err LED starts blinking whilst self-tuning is running, successful self-tuning
is prevented due to the control conditions. In this case, self-tuning was cancelled
by the controller. The controller continues operating with the old parameters in
automatic mode. In manual mode it continues with the old controller output va

-

lue.

KS 90-1 / KS 92-1 21 Self-tuning

Operation

3.5.10 Acknowledgement procedures in case of unsuccessful self-tuning

1. Press keys Ù and È simultaneously:

The controller continues controlling using the old parameters in automatic
mode. The Err LED continues blinking, until the self-tuning error was
acknowledged in the error list.

2. Press key Ò (if configured):

The controller goes to manual mode. The Err LED continues blinking,
until the self-tuning error was acknowleged in the error list.

3. Press key Ù :

Display of error list at extended operating level. After acknowledgement
of the error message, the controller continues control in automatic mode using
the old parameters.

Cancellation causes:

r page 15: "Error status self-tuning heating ( ADA.H) and cooling ( ADA.C)"

Self-tuning 22 KS 90-1 / KS 92-1

3.5.11 Examples for self-tuning attempts

(controller inverse, heating or heating/cooling)

Operation

Start: heating power switched on

Heating power Y is switched off (1).
When the change of process value X
was constant during one minute (2),
the power is switched on (3).
At the reversal point, the self-tuning at

­tempt is finished and the new parameter
are used for controlling to set-point W.

Start: heating power switched off

The controller waits 1,5 minutes (1).
Heating power Y is switched on (2).
At the reversal point, the self-tuning
attempt is finished and control to the
set-point is using the new parameters.

Self-tuning at the set-point a

The process is controlled to the
set-point. With the control deviation
constant during a defined time (1)
(i.e. constant separation of process value
and set-point), the controller outputs a
reduced correcting variable pulse (max.
20%) (2). After determination of the
control parameters using the process
characteristic (3), control is started
using the new parameters (4).

100%

100%

X

W

100%

0%

Start r

X

W

Y

0%

Star t r

X

W

Y

0%

Y

start r

1

blinks

1

blinks

2

r

1

blinks

t

3

2

2

3

4

t

t reversal point

t

t reversal point

t

Three-point controller a

The parameter for heating and cooling are

X

W

3

rt

determined in two attempts. The heating
power is switched on (1). Heating para
meters Pb1, ti1, td1 and t1 are de
termined at the reversal point. Control to
the set-point occurs(2). With constant
control deviation, the controller provides a
cooling correcting variable pulse (3). Af

-

-

+100%

Y0%

-100%

Start r

1

t reversal

point

2

4

t

5

-

ter determining its cooling parameters
Pb2, ti2, td2 and t2 (4) from the
process characteristics , control operation is started using the new parameters (5).

a

KS 90-1 / KS 92-1 23 Self-tuning

During phase 3, heating and cooling are done simultaneously!

Operation

y

3.6 Manual self-tuning

The optimization aid can be used with units on which the control parameters shall
be set without self-tuning.

For this, the response of process variable x after a step change of correcting varia
ble y can be used. Frequently, plotting the complete response curve (0 to 100%)
is not possible, because the process must be kept within defined limits. Values T

and x
be used to determine the maximum rate of increase v

(step change from 0 to 100 %) or ∆t and ∆x (partial step response) can

max

.

max

100%

Y

h

0%

x

t

Tg

X

max

-

g

{X

{t

Tu

y = correcting variable

Y

h

Tu = delay time (s)
Tg = recovery time (s)
X

max

V

max

The control parameters can be determined from the values calculated for delay
time T
according to the formulas given below. Increase Xp, if line-out to the set-point
oscillates.

= control range

= maximum process value

Xmax

=

Tg

, maximum rate of increase v

u

{{x

=

= max. rate of increase of process value

t

, control range Xhand characteristic K

max

t

Manual self-tuning 24 KS 90-1 / KS 92-1

Operation

Parameter adjustment effects

Parameter Control Line-out of disturbances Start-up behaviour

Pb1 higher increased damping slower line-out slower reduction of duty cycle

lower reduced damping faster line-out faster reduction of duty cycle

td1 higher reduced damping faster response to disturbances faster reduction of duty cycle

lower increased damping slower response to disturbances slower reduction of duty cycle

ti1 higher increased damping slower line-out slower reduction of duty cycle

lower reduced damping faster line-out faster reduction of duty cycle

Formulas

K = Vmax * Tu controller behavior Pb1 [phy. units] td1 [s] ti1 [s]

PID 1,7*K 2*Tu 2*Tu
With 2-point and
3-point controllers,

the cycle time must be
adjusted to

t1 / t2 ≤ 0,25 * Tu

PD 0,5 * K Tu OFF

PI 2,6 * K OFF 6*Tu

PKOFF OFF

3-point-stepping 1,7 * K Tu 2 * Tu

3.7 Second PID parameter set

The process characteristic is frequently affected by various factors such as pro­cess value, correcting variable and material differences.
To comply with these requirements, KS 90-1 can be switched over between two
parameter sets.
Parameter sets PArA and PAr.2 are provided for heating and cooling.

Dependent of configuration ( ConF/LOG/Pid.2), switch-over to the second pa­rameter set ( ConF/LOG/Pid.2) is via one of digital inputs di1, di2, di3,
key è or interface (OPTION).

g

Self-tuning is always done using the active parameter set, i.e. the second
parameter set must be active for optimizing.

KS 90-1 / KS 92-1 25 Second PID parameter set

Operation

3.8 Alarm handling

Max. three alarms can be configured and assigned to the individual outputs. Ge
nerally, outputs OuT.1... OuT.6 can be used each for alarm signalling. If more
than one signal is linked to one output the signals are OR linked. Each of the 3 li
mit values Lim.1 … Lim.3 has 2 trigger points H.x (Max) and L.x (Min), which
can be switched off individually (parameter = “OFF”). Switching difference
HYS.x and delay dEl.x of each limit value is adjustable.

Ü Operaing principle absolut alarm

L.1 = OFF

InL.1

H.1

HYS.1

LED

InH.1

* Operating principle relative alarm

L.1 = OFF

SP

InL.1

H.1

HYS.1

-

-

InH.1

LED

H.1 = OFF

InL.1

InL.1

H.1

L.1

LED

L.1

HYS.1

LED

HYS.1 HYS.1

InH.1

InH.1

LED

H.1 = OFF

InL.1

InL.1

2

LED

LED

HYS.1

HYS.1

L.1

SP

InH.1

L.1

SP

InH.1

H.1

HYS.1

LED

2

1: normally closed ( ConF/ Out.x/O.Act=1 ) (see examples in the drawing)
2: normally open ( ConF/ Out.x/O.Act= 0 )(inverted output relay action)

Alarm handling 26 KS 90-1 / KS 92-1