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

Πsetpoint processing with programmer and timer

 controller function with loop monitoring

Ž 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