advertisement
KS 40-1 / 41-1/ 42-1
Universal Industrial Controller
BluePort ® Front interface and BlueControl Software
Maintenance manager and error list
Three DIN sizes
Automatic/Manual key
Monitoring of heating current and input circuit
Timer and programmer
Extended limit signalling function with latch
Type tested to EN 14597 (replaces DIN 3440), cULus and GL
±
Universal continuous/switching version, i.e. reduced stocks
±
100 ms cycle time, i.e. also suitable for fast control loops
±
Customer-specific linearization for all sensors
±
Freely configurable analog output, e.g. as process value output
±
Settings can be blocked via password and internal switch for high security
±
Extended temperature range up to 60 °C allows mounting close to the process
±
Easy 2-point or offset measurement correction
±
Emergency operation after sensor break by means of the
„output hold“ function
±
Logical combination of digital outputs, e.g. for general alarm
±
Programmer with 4 segments and „end“ signal
±
RS 422/485 Modbus RTU interface
±
Built-in transmitter power supply
±
Splash-water proof front (IP 65)
APPLICATIONS
Ø
Furnaces and ovens
Ø
Burners and boilers
Ø
Plastics processing
Ø
Driers
Ø
Climatic chambers
Ø
Heat treatment plants
Ø
Sterilizers termined separately, thus ensuring an optimum match to the process.
DESCRIPTION
The universal temperature controller
KS 4X-1 are intended for universal, precise, and cost-effective control tasks in all branches of industry. For this, the unit provides simple 2-point
(on/off) control, continuous PID control, or 3-point stepping control. The process value signal is connected via a universal input. A supplementary analog input can be used for heating current measurement or as an external set-point input.
Every KS 4X-1 has three process outputs that can be 3 relays or 2 relays plus a universal output. This universal output can be used for operating a solid-state relay, a continuous current/voltage output or to energize a two-wire transmitter.
Plug-in module
KS 4X-1 controllers are built as plug-in modules. This enables them to be replaced very quickly without tools, and without disturbing the wiring.
Display and operation
Clear informations are given by ten indicator LED’s in the front panel that display operating mode, I/O states, and errors. The auto/manual key switches the controller into the manual mode directly, without lengthy operating sequences. If required, the direct switch over can be disabled or the key can be configured e.g. to start the internal timer. This results in a level of operational safety that is usually found only in controllers of a higher price category.
Front interface and Engineering
Tools
Control parameter adjustment in seconds has now also been implemented in the KS 40 class of instruments.
Via the BlueControl software incl. its simulation functions, and especially the convenient BluePort ® front panel interface, the required set-up for a specific control task can be determined without a detailed study of the operating instructions.
Off cause almost all adjustments can be done comfortably over the instrument front. (see page 7, BlueControl)
Self-tuning
During start-up, the self-tuning function determines the optimum settings for fast line-out without overshoot.
With three-point controller configuration, the „cooling“ parameters are de-
Password protection
If required, access to the various operating levels can be protected with a password. Similarly, access to a complete level can be blocked.
2
TECHNICAL DATA
INPUTS
SURVEY OF THE INPUTS
Input
INP1
INP2 di1 di2 (option) di3 (option)
Used for: x (process value)
Heating current, ext. set-point
Operation disabled, switch-over to second set-point SP.2, external set-point SP.E, fixed output signal Y2, manual operation, controller off, disabled auto/manual key, reset stored alarms, timer start (
= Y2)
PROCESS VALUE INPUT INP1
Resolution:
Decimal point:
> 14 bits
0 to 3 decimals
Digital input filter: adjustable 0,000...9999 s
Scanning cycle: 100 ms
Measured value correction: 2-point or offset correction
Table 1 Thermocouple ranges
Thermocouple
K
N
L
J
S
R
Fe-CuNi (DIN)
Fe-CuNi
NiCr-Ni
Nicrosil/Nisil
PtRh-Pt 10%
PtRh-Pt 13% special
Range
-100...900 °C
-100...1200 °C
-100...1350 °C
-100...1300 °C
-148...1652 °F
-148...2192 °F
-148...2462 °F
-148...2372 °F
0...1760 °C
0...1760 °C
-25 ...75 mV
32...3200 °F
32...3200 °F
Table 2 Resistance transducers
Type
Pt 100
Pt100
Pt1000
Resistance *
Sensor current
0,2mA
Range
-200...100 (150)°C -328...212 (302)°F
-200...850 °C -328...1562 °F
-200...850 °C
4500
W
-328...1562 °F
* The characteristic of a KTY 11-6 is preadjusted (-50...150°C)
Table 3 Current and voltage
Range
0-10 Volt
0-20 mA
Input resistance
» 110 kW
49
W (voltage requirement £ 2,5 V)
Electrical connections:
Thermocouples (Table 1)
Input impedance: ³ 1 MW
Effect of source resistance: 1 mV/W
Cold junction compensation
Max. additional error ± 0,5 K
Sensor break monitoring
Sensor current: £ 1mA
Operating sense configurable (see page 4)
Resistance thermometer
Connection:
Lead resistance:
Input circuit monitor:
3-wire max. 30
W
Break and short circuit
Resistance measuring range
The BlueControl software can be used to match the input to the sensor KTY di2
Modbus RTU
RGND
DATA B
RXD-B
GND
RXD-A
TXD-B
DATA A TXD-A
RS485 RS422 di3
U
T
Option
11
12
13
14
15
(16)
17
8
9
10
5
6
7
1
(2)
3
4
7
8
9
4
5
6
1
2
3
10
11
12
13
14
15
L
N
Logic
U
Accuracy
£ 2 K
£ 2 K
£ 2 K
£ 2 K
£ 2 K
£ 2 K
£ 0,1 %
Accuracy
£ 1 K
£ 2 K
£ 0,1 %
Accuracy
£ 0,1 %
£ 0,1 %
90...250V
24V AC/DC
Resolution (
Æ)
0,1 K
0,1 K
0,2 K
0,2 K
0,2 K
0,2 K
0,01 %
Resolution (
Æ)
0,1 K
0,1 K
0,01 %
Resolution (
Æ)
0,6 mV
1,5 mA
OUT1
OUT2
OUT3
HC mA mA
INP2 di1
0..10 V*
INP1
* Pay attention to the internal switch!
Dimensions (mm): min.48
(
1.89’’)
92 +0,8 92 +0,8
10
(0.4”)
(4.65”)
118
SP.X
126
125 run
Ada
Err
1...10
0.04-0.4” KS 42-1 universal
SP.x
run
Ada
Err
1 2 3 OK
45 +0,6
KS 40-1 universal
48 (1.89”)
SP.x
126 run
125
Ada
Err
1 2
KS 41-1 universal
3 OK
96 (3.78”)
(4.65”)
118
10
(0.4”)
96 (3.78”)
(4.65”)
118
10
(0.4”)
KS 40-1 KS 41-1
KS 40-1 / KS 41-1 / KS 42-1
KS 42-1
11-6 (characteristic is stored in the controller).
Physical measuring range:
Linearization segments
0...4500
W
16
Current and voltage signals
Span start, end of span:
Scaling:
Linearization:
Decimal point:
Input circuit monitor: anywhere within measuring range selectable -1999...9999
16 segments, adaptable with BlueControl adjustable
12,5% below span start
(2mA, 1V)
SUPPLEMENTARY INPUT INP2
Resolution: > 14 bit
Scanning cycle: 100 ms
Accuracy: better 0,1 %
Heating current measurement via current transformer
Measuring range: 0...50 mA AC
Scaling: adjustable -1999..0,000..9999 A
Current measurement range
Input resistance
Span: approx. 120 W configurable within
0 to 20mA
Scaling: adjustable -1999...9999
Input circuit monitor: 12,5% below span start
(4..20mA
® 2mA)
CONTROL INPUTS DI2, DI3
(OPTION)
Configurable as switch or push-button !
Optocoupler input for active triggering
Nominal voltage: 24 V DC, external
Current sink (IEC 1131 Type 1)
Logic „0":
Logic „1":
Current requirement:
-3...5 V
15...30 V approx. 5 mA
CONTROL INPUT DI1
Configurable as direct or invers switch or push-button !
Connection of a potential-free contact suitable for switching „dry“ circuits.
Switched voltage:
Switched current:
2,5 V
50 mA
TRANSMITTER SUPPLY U
T
(OPTION)
Output: 22 mA / ³ 18 V
If the universal output OUT3 is used there may be no external galvanic connection between measuring and output circuits!
Example of the linkage of the internal functions:
(Y2/SP2)
ÈÌ
SP.2
SP.E
INP1
INP2
FAi.1
FAi.2
#
Ò
weff ff Y.
xeff y1 y2
LP.AL
yPID xw or
OUT1 or
OUT2 or
OUT3
HCA
Ì
HC.AL
HC.SC
setpoint processing with programmer and timer
controller function with loop monitoring
limit monitoring, configurable with latch and suppression
heating current monitoring
output processing with logic or-combination and inverting
analog inputs with logical sensor fail signal
digital inputs and Ò-key with lock function
KS 40-1 / KS 41-1 / KS 42-1 3
OUTPUTS
SURVEY OF THE OUTPUTS
Output
OUT1
OUT2
(relay)
Used for:
Control output heating/cooling or Open/Close, limit contacts, alarms, timer or programmer
End *
OUT3
(Relay or logic) as OUT1 and OUT2
OUT3
(continuous)
Control output, process value, set-point, control deviation, transmitter supply 13 V / 22 mA
* All logic signals can be OR-linked !
OUT3 AS UNIVERSAL OUTPUT
Galvanically isolated from the inputs.
Freely scalable
DA-converter limiting frequency T
90
Limiting frequency of the complete
: 50 ms continuous controller: > 2 Hz
Resolution: 11 bits
Current output
0/4...20 mA, configurable.
Signal range:
Load:
Load effect:
Resolution:
Error:
0...approx. 21,5 mA
£ 500 W
0,02 % / 100 W
£ 22 mA (0,1%)
£ 40 mA (0,2%)
Galvanic isolations:
Safety isolation
Functional isolation
Mains supply Process value input INP1
Supplementary input INP2
Digital input di1
Relay outputs OUT1,2 RS 422/485 interface
Relay output OUT3 Digital inputs di2, 3
Universal output OUT3
Transmitter supply UT
Timer modes 1 and 2
RELAY OUTPUTS OUT1, OUT2
Contacts: 2 NO contacts with common connection
Max. contact rating: 500 VA, 250 VAC, 2A at
48...62 Hz, resistive load
Min. contact rating: 6 V, 1 mA DC
Duty cycle electric for I = 1A/2A: ³
800,000 / 500,000 (at ~
250V / (resistive load))
OUT3 USED AS RELAY OUTPUT
Contacts: Potential-free changeover contact
Max. contact rating: 500 VA, 250 VAC, 2A at
48...62 Hz, resistive load
Min. contact rating: 5 V, 10 mA AC/DC
Duty cycle electric for I = 1A/2A: ³
1,000,000 / 600,000 (at
~ 250V / (resistive load))
Note:
If the relays OUT1...OUT3 operate external contactors, these must be fitted with RC snubber circuits to manufacturer specifications to prevent excessive switch-off voltage peaks.
Voltage output
0/2...10V, configurable
Signal range:
Load:
Load effect:
Resolution:
Error:
0...11 V
³ 2 kW no Effect
£ 11 mV (0,1%)
£ 20 mV (0,2%)
OUT3 used as transmitter supply
Output: 22 mA / ³ 13 V
OUT3 used as logic output
Load £ 500 W
Load > 500 W
0/ £ 20 mA
0/> 13 V start start blink t.SP
t.SP
Timer modes 3 and 4
Timer mode 5
1
2
End
3
4
End start t.P
4
Display and operation:
3 yellow LEDs for the output states green “OK”-LED
1 2 3 OK second or external setpoint rate of change limited manual operation automatic/manual key
SP.X
126
125 run
Ada
Err process value programmer or timer runs selftuning is running error list setpoint, actuating value, parameter
BluePort front interface
KS 40-1 universal enter-key up and down keys
KS 40-1 / KS 41-1 / KS 42-1
Timer mode 6
SP blink start
SP.2
t.SP
End
SP
FUNCTIONS
Control behaviour
•
Signaler with adjustable switching differential (ON/OFF controller)
•
PID controller (2-point and continuous)
•
Delta / Star / Off or 2-point controller with switch over from partial to full load
•
2 x PID (heating/cooling, 3-point and continuous))
•
3-point stepping controller
Self-tuning control parameters or adjustable manually via front keys or
BlueControl software.
Set-point functions
•
Adjustable set-point gradient
0,01...9999 °C/min
•
Set-point control
• Set-point/cascade control
•
Program controller with 4 segments
(set-point/section time)
•
Timer
Timer
Time t.SP adjustable from 0,1 to 9999 min
Timer Start:
•
Mains on
•
Control input
• Ò-key (=Y2 switch-over)
•
Direct adjustment of running time
Behaviour with sensor break or short circuit:
•
Control outputs switched off
•
Switch-over to a safe output value
• Switch-over to a mean output value
LIMIT SIGNALLING FUNCTIONS
Max., Min. or Max./Min. monitoring with adjustable hysteresis.
Signals which can be monitored:
•
Process value
•
Control deviation
• Control deviation with suppression during start-up or set-point changes
• Effective set-point
•
Output signal Y
Functions
•
Input signal monitoring
• Input signal monitoring with latch
(reset via front key or digital input)
Several limit signals or alarms can be
OR-linked before being output.
Applications: Release of a brake with motor actuators, general alarms, etc.
OPERATION AND DISPLAY
Display
KS40-1 / KS41-1
Process value: 10,5 mm LED
Lower display: 7,8 mm LED
KS42-1
19 mm LED
10,5 mm LED
ALARMS
Heating current alarm
•
Overload and short circuit
•
Open circuit and short circuit
Limit value adjustable 0...9999 A
Control loop alarm
Automatic detection if there is no response of the process to a change of output value.
Sensor break or short circuit
Depending on selected input type, the input signal is monitored for break and short circuit.
POWER SUPPLY
Depending on version:
AC SUPPLY
Voltage:
Frequency:
Power consumption
90...260 VAC
48...62 Hz approx. 7 VA
UNIVERSAL SUPPLY 24 V UC
AC voltage:
Frequency:
DC voltage:
Power consumption:
20,4...26,4 VAC
48...62 Hz
18...31 V DC class 2 approx: 7 VA (W)
BEHAVIOUR WITH POWER
FAILURE
Configuration, parameters, and adjusted set-points, control mode:
Non-volatile storage in EEPROM
MAINTENANCE MANAGER
Display of error signals, warnings, and latched limit messages in the error list.
Signals are latched, and can be reset manually.
Possible signals in the error list:
Sensor break, short circuit, reversed polarity
Heating current alarm
Control loop alarm
Fault during self-tuning latched limit messages e.g. re-calibration warning
(If the adjusted operating hours are exceeded a message is displayed) e.g. maintenance interval of actuator
(If the adjusted switching cycles are exceeded a message is displayed)
Internal fault (RAM, EEPROM, ...)
BluePort
®
FRONT INTERFACE
Connection of PC via PC adapter (see
„Accessories“). The BlueControl software is used to configure, set parameters, and operate the KS 40-1.
BUS INTERFACE (OPTION)
Galvanically isolated
Physical:
Protocol:
Transmission speed:
2400, 4800, 9600, 19.200 bits/s
RS 422/485
Modbus RTU
Address range: 00...99
Number of controllers per bus: 32
Repeaters must be used to connect more controllers.
ENVIRONMENTAL CONDITIONS
Flashing Error LED indicates active alarm in the error list:
Protection modes
Front panel: IP 65
Housing: IP 20
Terminals: IP 00
SP.x
126
125 run
Ada
Err
Permissible temperatures
For specified accuracy: 0...60°C
Warm-up time: < 15 minutes
Temperature effect: < 100ppm/K
For operation:
For storage:
-20...65°C
-40...70°C
KS 40-1 / KS 41-1 / KS 42-1 5
Humidity
75% yearly average, no condensation
Shock and vibration
Vibration test Fc (DIN 68-2-6)
Frequency:
Unit in operation:
10...150 Hz
1g or 0,075 mm
Unit not in operation: 2g or 0,15 mm
Shock test Ea (DIN IEC 68-2-27)
Shock:
Duration:
15g
11ms
Electromagnetic compatibility
Complies with EN 61 326-1
•
Complies with the immunity requirements for continuous, unattended operation
•
Complies with the emmission requirements class B for rural areas
•
Surge disturbances may increase the measurement error
Mounting
Panel mounting with two fixing clamps at top/bottom or left/right
Close mounting possible
Mounting position:
Weight: not critical
0,27 kg (9.52 oz)
Accessories supplied with unit
Operating instructions
2 fixing clamps
GENERAL
Housing
Material: Makrolon 9415, flame-retardant
Flammability class: UL 94 VO, self-extinguishing
Plug-in module, inserted from the front
Safety tests
Complies with EN 61010-1 (VDE
0411-1):
Over voltage category II
Contamination class 2
Working voltage range 300 VAC
Protection class II
Certifications
Type tested to EN 14597 (replaces
DIN 3440)
With certified sensors applicable for:
•
Heat generating plants with outflow temperatures up to 120°C to DIN 4751
•
Hot-water plants with outflow temperatures above 110°C to DIN 4752
•
Thermal transfer plants with organic transfer media to DIN 4754
•
Oil-heated plants to DIN 4755 cULus-certification
(Type 1, indoor use)
File: E 208286
Electrical connections
Depending on version:
•
Flat-pin connectors 1 x 6,3 mm or
2 x 2,8 mm to DIN 46 244
•
Screw terminals for conductor cross-section from 0,5 to 2,5 mm²
6 KS 40-1 / KS 41-1 / KS 42-1
ACCESSORY EQUIPMENT
BlueControl (Engineering Tool)
PC-based program for configuring, setting parameters, and operating
(commissioning) the KS 40-1 controller. Moreover, all the settings are saved, and can be printed on demand.
Depending on version, a powerful data acquisition module is available, complete with trend graphics.
Software requirements:
Windows 95/98/NT/2000.
The built-in simulation serves to test the controller settings, but can also be used for general training and observing the interaction between controller and control loop.
BlueControl, versions and functionality:
Configurations that can only be implemented via the BlueControl software (not via the front-panel keys):
Two parameters are hidden:
• Customer-specific linearizations
•
Enable „forcing“ for inputs/outputs.
Forcing allows to write the analog and digital inputs and outputs via
Modbus interface.
• Adjustment of limits for operating hours and switching cycles
• Switch-over to 60 Hz mains frequency
• Disable operator actions and operating levels, plus password definition
• Prevent automatic optimization of cycle times T1, T2
Hardware requirements:
A PC adapter (see „Accessories“) is required for connecting the controller.
Updates and demo software can be downloaded from: www.pma-online.de
KS 40-1 / KS 41-1 / KS 42-1 7
ORDERING INFORMATION
K S 4
KS 40-1 (1/8 DIN)
KS 41-1 (1/8 DIN "landscape" )
0
1
1
KS 42-1 (1/4 DIN)
Flat-pin connectors
Screw terminals
90..250V AC, 3 relays
24VAC / 18..30VDC, 3 relays
90..250V AC, 2 relays + mA/logic
2
24VAC / 18..30VDC, 2 relays +mA/logic
0
1
0
1
2
3 no option 0
RS422/485 + Transmitter power supply +di2, di3 1
Standard configuration
Configuration to specification no manual manual german manual english manual french
Standard (CE certified) cULus-certified (with screw terminals only)
EN 14597 (replaces DIN 3440) certified
GL (German Lloyd) certified
0 0
0
9
E
F
0
D
D
G
0
U
00
ACCESSORIES
Description
Current converter 50A AC
PC adapter, for connecting BlueControl software to the BluePort ®
Standard rail adapter
Adhesive set of physical dimension labels with 31 different dimensions and 4 empty labels
Operating manual
Operating manual
German
English
Operating manual
BlueControl Mini
French
German/English/french
BlueControl Basic
BlueControl Expert
German/English/french
German/English/french
Order no.
9404-407-50001
9407-998-00001
9407-998-00061
4012-140-66041
9499-040-62718
9499-040-62711
9499-040-62732 www.pma-online.de
9407-999-11001
9407-999-11011
PMA
Prozeß- und Maschinen- Automation GmbH
P.O. Box 31 02 29
D-34058 Kassel
Tel.: +49 - 561- 505 1307
Fax: +49 - 561- 505 1710
E-mail: [email protected]
Internet: http://www.pma-online.de
Your local representative:
Printed in Germany - Edition 07/2011- Subject to change without notice - 9498 737 39913
advertisement
* Your assessment is very important for improving the workof artificial intelligence, which forms the content of this project