WIKA CS4S User Manual
Temperature Indicating Controller, Model CS4S
Operating Instructions
WIKA Operating Instructions CS4S V1.1 • 10/2006
WIKA Alexander Wiegand GmbH & Co. KG
Alexander-Wiegand-S t raße 30
63911 Klingenberg/Germany
Phone (+49) 93 72/132-0
Fax (+49) 93 72/132-406
E-Mail
www.wika.de
info@wika.de
Operating Instructions Temperature Indicating Controller CS4S
Preface
Thank you for the purchase of our microcomputer based temperature indicating controllers CS4S.
This manual contains instructions for the mounting, functions, operations and notes when operating the CS4S.
For model confirmation and unit specifications, please read this manual carefully before starting operation.
To prevent accidents arising from the misuse of this controller, please ensure the operator using it receives this
manual.
Caution
• This instrument should be used according to the specifications described in the manual.
If it is not used according to the specifications, it may malfunction or cause fire.
• Be sure to follow the warnings, cautions and notices. If not, it could cause serious injury or malfunction.
• Specifications of the CS4S and the contents of this instruction manual are subject to change without notice.
• Care has been taken to assure, that the contents of this instruction manual are correct, but if there are any
doubts, mistakes or questions, please inform our sales department.
• This instrument is designed to be installed in a control panel. If not, measures must be taken to ensure that the
operator cannot touch power terminals or other high voltage sections.
• Any unauthorized transfer or copying of this document, in part or in whole, is prohibited.
• WIKA is not liable for any damages or secondary damages incurred as a result of using this product, including
any indirect damages.
SAFETY PRECAUTIONS
(Be sure to read these precautions before using our products.)
The safety precautions are classified into categories: “Warning” and “Caution”.
Depending on circumstances, procedures indicated by
results, so be sure to follow the directions for usage.
Caution may be linked to serious
Warning
Procedures which may lead to dangerous conditions and cause death or serious
injury, if not carried out properly.
Caution
Procedures which may lead to dangerous conditions and cause superficial to medium
injury or physical damage or may degrade or damage the product, if not carried out
properly.
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Operating Instructions Temperature Indicating Controller CS4S
1. Installation precautions
Caution
This instrument is intended to be used under the following environmental
conditions (IEC61010-1):
Overvoltage category
Mount the controller in a place with:
• A minimum of dust, and an absense of corrosive gasses
• No flammable, expolsive gasses
• No mechanical vibrations or shocks
• No exposure to direct sunlight
• An ambient temperature of 0 … 50 °C (32 … 122 °F), that does not change suddenly
• An ambient non-condensing humidity of 35 … 85 %RH
• No large capacity electromagnetic switches or cables through which large current is flowing.
• No water, oil or chemicals or where the vapors of these substances can come into direct
contact with the unit
Note: Do not install this instrument near flammable material even though the case of this
instrument is made of flame resisting resin. Avoid setting this instrument directly on
flammable material.
, Pollution degree 2
2. Wiring precautions
Caution
• Use the solderless terminal with an insulation sleeve that fits in the M3 screw when wiring the
CS4S.
• The terminal block of this instrument is designed to be wired from the left side.
The lead wire must be inserted from the left side of the terminal, and fastened with the terminal
screw.
• Tighten the terminal screw within the specified torque.
If excessive force is applied to the screw when tightening, the screw or case may be damaged.
• Do not apply a commercial power source to the sensor which, is connected to the input
terminal nor allow the power source to come into contact with the sensor, as the input circuit
may be burnt out.
• This controller has no built-in power switch, circuit breaker or fuse. It is necessary to install
them near the controller.
(Recommended fuse: Time-lag fuse, rated voltage 250V AC, rated current 2A)
• When using a 24V AC/DC for the power source, do not confuse the polarity when it is DC.
3. Running and maintenance precautions
Caution
• It is recommended that PID auto-tuning be performed on the trial run.
Do not touch live terminals. This may cause electric shock or problems in operation.
•
• Turn the power supplied to the instrunment OFF when retightening the terminal and cleaning.
Working or touching the terminal with the power switched ON may result in Electric Shock
causing severe injury or death.
• Use a soft, dry cloth when cleaning the instrument.
(If paint thinner is used, it might deform or tarnish the unit.)
• As the display section is vulnerable, do not strike or scratch it with a hard object or press hard
on them
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Operating Instructions Temperature Indicating Controller CS4S
--- CONTENTS ---
1. Model name and Order Code ····················································································· 6
2. Name and functions of the sections ········································································ 7
3. Mounting to control panel
3.1 Site selection ····················································································································8
3.2 External dimension ··········································································································· 8
3.3 Panel cutout ·····················································································································8
3.4 CT (current transformer) external dimension ····································································9
3.5 Mounting ·························································································································· 9
4. Wiring connection ······································································································· 10
5. Setup ·································································································································11
5.1 Setup flow chart ············································································································· 12
5.2 Main setting mode
SV1 ·································································································································14
SV2 ·································································································································14
5.3 Sub setting mode
AT setting/Auto-reset setting ··························································································· 14
OUT1 proportional band setting ······················································································ 14
OUT2 proportional band setting ······················································································ 14
Integral time setting ········································································································· 14
Derivative time setting ····································································································· 14
ARW (Anti-reset windup) setting ····················································································· 14
OUT1 proportional cycle setting ······················································································ 14
OUT2 proportional cycle setting ······················································································ 15
A1 setting ························································································································ 15
A2 setting ························································································································ 15
HB (Heater burnout alarm) setting ··················································································· 15
LA (Loop break alarm) action time setting ······································································· 15
LA (Loop break alarm) action span setting ······································································ 15
5.4 Auxiliary function setting mode 1
Setting value lock selection ·····························································································16
SV high limit setting ········································································································· 16
SV low limit setting ·········································································································· 16
Sensor correction setting ································································································· 16
Communication protocol selection ··················································································· 16
Instrument number setting ······························································································· 16
Data transfer rate selection ····························································································· 16
Parity selection ················································································································16
Stop bit selection ·············································································································16
5.5 Auxiliary function setting mode 2
Input type selection ········································································································· 17
Scaling high limit setting ·································································································· 17
Scaling low limit setting ··································································································· 17
Decimal point place selection ·························································································· 17
PV filter time constant setting ·························································································· 17
OUT1 high limit setting ···································································································· 17
OUT1 low limit setting ····································································································· 18
OUT1 ON/OFF action hysteresis setting ········································································· 18
OUT2 action mode selection ··························································································· 18
OUT2 high limit setting ···································································································· 18
OUT2 low limit setting ····································································································· 18
Overlap band/Dead band setting ····················································································· 18
OUT2 ON/OFF action hysteresis setting ········································································· 18
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Operating Instructions Temperature Indicating Controller CS4S
A1 action selection ·········································································································· 18
A2 action selection ·········································································································· 18
A1 action Energized/Deenergized selection ···································································· 18
A2 action Energized/Deenergized selection ···································································· 18
A1 hysteresis setting ······································································································· 19
A2 hysteresis setting ······································································································· 19
A1 action delayed timer setting ······················································································· 19
A2 action delayed timer setting ······················································································· 19
Direct/Reverse action selection ······················································································· 19
AT bias setting ·················································································································19
SVTC bias setting ············································································································ 19
SV2 indication selection ·································································································· 19
Output status selection when input burnout ····································································· 19
OUT/OFF key function selection ····················································································· 19
5.6 Auto/Manual control func tion ·························································································· 20
5.7 Control output OFF function ··························································································· 20
5.8 Output manipulated variable indication ·········································································· 20
6. Running ·························································································································· 21
7. Action explanation
7.1 OUT1 action ··················································································································· 21
7.2 OUT1 ON/OFF action ····································································································· 22
7.3 Temperature Alarm action ······························································································ 23
7.4 Heater burnout alarm action (option) ·············································································· 23
7.5 OUT2 (Heating/Cooling control) action (option) ····························································· 24
7.6 OUT2 (Heating/Cooling control) action (When setting Dead band) (option) ··················· 25
7.7 OUT2 (Heating/Cooling control) action (When setting Overlap band) (option) ··············· 26
8. PID auto-tuning of this controller ··········································································· 27
9. Specifications
9.1 Standard specifications ·································································································· 28
9.2 Optional specifications ··································································································· 31
10.Troubleshooting
10.1 Indication ······················································································································ 33
10.2 Key operation ··············································································································· 34
10.3 Control ·························································································································· 34
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Operating Instructions Temperature Indicating Controller CS4S
1. Model Name and Order Code
CS4S - 3 A / M - B - - -... Series name CS4S
Control
3 PID (setable control parameter)
characteristic
Alarm 1 (A1) A Process value monitoring, output relay
Control output
R Relay
S Logic level (DC 0/12 V) for solid state relay
A Analogue current signal (4 ... 20 mA)
Input M Multi-function input (input configuration setable)
H AC 100 ... 240 V, 50 ... 60 Hz Power supply
L AC/DC 24 V
Case colour B Black
B Factory adjustment Instrument configuration
# (?) To customers specification
Options
(4)
2AS
Alarm output 2: process value monitoring
(4)
2AR
Alarm output 2: control loop monitoring
(4)
2AL
W10
W11
W12
W15
DT2
Alarm output 2: process value and control loop
(4) (5)
(4) (5)
(4) (5)
(4) (5)
(4)
monitoring with common terminals
Heater burnout alarm for 1 phase (max. 5 A)
Heater burnout alarm for 1 phase (max. 10 A)
Heater burnout alarm for 1 phase (max. 20 A)
Heater burnout alarm for 1 phase (max. 50 A)
2. control output (three step control) non-contact relay
SV2 Parameter memory for 2 set values, external
selectable by connection terminals
Serial communication RS 485
Shunt resistor 50
Ω for input signals 0/4 ... 20 mA
CR5
R50
(6)
KAB Terminal cover
(1)
(2)
(3)
(1) PID, PI, PD, P and ON/OFF action are programmable.
(2) 9 types of alarm action, no alarm action and energized/deenergized are selectable by key operation.
(3) The input configuration can be selected from the user by the front keys.
(4) Only 2 options can be added from Alarm output 2, Heater burnout alarm and 2. control output.
(5) For control output analogue current signal heater burnout alarm cannot be added.
(6) When serial communication is added, SV1/SV2 external selection (standard function) does not work.
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Operating Instructions Temperature Indicating Controller CS4S
2. Name and functions of the sections
Indications:
(1) PV PV display
Indicates the process variable (PV) with a
red LED.
(2) SV SV display
Indicates the setting value (SV) or
manipulated variable (MV) with a green LED.
(3) SV1 Set value 1 indicator
When set value 1 (SV1) is selected, a green
LED lights.
(4) SV2 Set value 2 indicator
When set value 2 (SV2) is selected, a yellow
LED lights.
(5) OUT1 Control output 1 (OUT1) indicator
When OUT1 is ON, a green LED lights.
(In the case of DC current output type it blinks in a 0.25 second cycle, corresponding
to the output manipulated variable.)
(6) OUT2 Control output 2 (OUT2) indicator
When OUT2 is ON, a yellow LED lights.
(7) A1 Alarm 1 (A1) indicator
When A1 output is ON, a red LED lights.
(8) EVT EVT indicator
When Event output (options: 2Ax or W1x) is ON, a red LED lights up.
(9) AT Auto-tuning (A T) indicator
When Auto-tuning or Auto-reset is active, a yellow LED blinks.
(10) TX/RX TX/RX indicator
When serial communication TX (transmitting) is outputted, a yellow LED lights.
Keys:
(11)
Increase key
Increases numeric value of the setting value.
(12)
Decrease key
Decreases numeric value of the setting value.
(13) MODE MODE key
Selects the setting mode or registers the setting value.
(By pressing the MODE key, the setting value or selected value can be registered)
(14)
OUT
/
OFF
OUT
/
key
OFF
The control output OFF function or Auto/Manual control function can be switched.
(To cancel the control output OFF function, press the
(1)
(2)
(3)
(4)
(11) (12) (13) (14)
OUT
/
key again for approx. 1 second.)
OFF
(5)
(6)
(7)
(8)
(9)
(10)
Notice
When setting the specifications and functions of this controller , connect the terminals 1 and 2 for power
source first, then set them referring to “5. Setup” before performing “3. Mounting to control panel” and
“4. Wiring connection”.
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Operating Instructions Temperature Indicating Controller CS4S
3. Mounting to control panel
3.1 Site selection
This instrument is intended to be used under the following environmental conditions (IEC61010-1):
Overvoltage category
Mount the controller in a place with:
• A minimum of dust, and an absence of corrosive gases
• No flammable, explosive gasses
• Few mechanical vibrations or shocks
• No exposure to direct sunlight
• An ambient temperature of 0 … 50 °C (32 … 122 °F), which does not change rapidly
• An ambient non-condensing humidity of 35 … 85 %RH
• No large capacity electromagnetic switches or cables through which large current is flowing
• No water, oil or chemicals or where the vapors of these substa nces can come into direct conta ct with the
controller
3.2 External dimension
48
(Fig. 3.2-1)
3.3 Panel cutout
75
controller, IP66 specification will not be fulfilled.
45
+0.5
0
(Fig. 3.3-1)
, Pollution degree 2
Gasket
11.5
0
+0.5
45
n x 48-3
Screw type mounting bracket
59.7
44.5
95
0
+0.5
Lateral close mounting
n: Number of units mounted
+0.5
0
Caution: If lateral close mounting is used for the
45
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Operating Instructions Temperature Indicating Controller CS4S
3.4 CT (Current transformer) external dimension
CTL-6S (for 5A, 10A, 20A) CTL-12-S36-10L1 (for 50A)
(Fig. 3.4-1)
3.5 Mounting
Mount the controller vertically to fulfill the Dust-proof/Drip-proof specification (IP66).
Mountable panel thickness: Within 1 to 15 mm
Insert the controller from the front side of the panel.
Attach the mounting brackets by the holes at the top and bottom of the case and secure the controller in
place with the screws.
(Fig.3.5-1)
Warning
As the case is made of resin, do not use excessive force while scre wing in the mounting
bracket, or the case or screw type mounting bracket could be damaged.
The torque is approximately 0.12 Nm.
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Operating Instructions Temperature Indicating Controller CS4S
4. Wiring connection
Warning
Turn the power supply to the instrument off before wiring or checking it.
Working or touching the terminal with the pow er switched on ma y result i n El ectri c Sho ck
causing severe injury or death.
24V AC/DC
(Fig. 4-1)
• OUT1 : Control output 1
• OUT2 : Control output 2
• A1 : Alarm 1 output
• EVT : Event output (A2 output, Heater burnout alarm output, Loop break alarm output)
• CT : CT input
• SV2 : Main setting 2 (SV2)
• RS-485 : Serial communication (RS-485)
• TC : Thermocouple
• RTD : Resistance temperature detector
• DC : DC current (DC mA), DC voltage (DC V)
50Ω : Shunt resistor 50Ω for input signal DC current
•
POWER SUPPLY
100 to
240V AC
OUT
A1
2
EVT
NO
3A
250V
AC
NO
0.3A
250V
AC
OUT1CT NO
YA
SV2
YB
50Ω
SG
RS-485 TC RTD
DC
mA
DC
V
3A
250V
AC
A
B
B
Notice
• The terminal block of the CS4S is designed to be wired from the left side. The lead wire must be
inserted from the left side of the terminal, and fastened by the terminal screw.
• Dotted lines show options.
• Use a thermocouple and compensating lead wire according to the sensor input specification of this
controller.
• Use the 3-wire RTD which corresponds to the input specification of this controller.
• This controller does not have built-in power switch, circuit breaker or fuse. Therefore, it is necessary
to install them in the circuit near the external controller.
(Recommended fuse: Time-lag fuse, rated voltage 250V AC, rated current 2A)
• When using a 24V AC/DC for the power source, do not confuse the polarity when it is DC.
• When using a relay contact output type, externally use a relay according to the capacity of the load to
protect the built-in relay contact.
• When wiring, keep input wires (thermocouple, RTD, etc.) away from AC sources or load wires to
avoid external interference.
• Do not apply a commercial power source to the sensor connected to the input terminal nor allow the
power source to come into contact with the sensor.
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Operating Instructions Temperature Indicating Controller CS4S
Lead wire solderless terminal
Use a solderless terminal with isolation sleeve that fits in the M3 screw as shown below.
The torque is approximately 0.6 Nm to 1.0 Nm.
3.2mm
3.2mm
5.8mm or less
5.8mm or less
(Fig. 4-2)
Option: Heater burnout alarm
(1) This alarm is not available for detecting heater current
under phase control.
(2) Use the current transformer (CT) provided and pass one
CT
(11)
CT input Terminal
(12)
Power
supply
lead wire of the heater circuit into the hole of the CT.
(3) When wiring, keep the CT wire away from AC sources
or load wires to avoid the external interference.
(Fig. 4-3)
Heater
5. Setup
Wire the power terminals only. After the power is turned on, the sensor input characters and temperature
unit are indicated on the PV display and the input range high limit value is indicated on the SV display for
approximately 3 seconds (Table 5-1).
If any other value is set during the scaling high limit setting, the set value is indicated on the SV display.
During this time, all outputs and the LED indicators are in OFF status. Control will then start and the input
value will be indicated on the PV display and main setting value (SV) will be indicated on the SV display.
(While control output OFF function is working,
is indicated on the PV display.)
(Table 5-1)
Sensor input
K
J
R
S
B
E
T
N
PLC (W/Re5-26)
Pt100
JPt100
4 … 20 mA DC
0 … 20 mA DC
0 … 1V DC
0 … 5V DC
1 … 5V DC
0 … 10V DC
°C °F
PV display SV display PV display SV display
Scaling high
limit value
Scaling high
limit value
V1.1
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