PMA KS 50-1 Operating Manual
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PMA KS 50-1 Operating Manual

Industrial controller, universal line
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PMA Prozeß- und Maschinen-Automation GmbH
Industrial controller KS 50-1and KS 52-1
KS50-1
KS52-1
KS50-1
KS52-1
Operating manual
English
9499-040-62811
Valid from: 07/2011

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  • Page 1 PMA Prozeß- und Maschinen-Automation GmbH Industrial controller KS 50-1and KS 52-1 KS50-1 KS52-1 KS50-1 KS52-1 Operating manual English 9499-040-62811 Valid from: 07/2011...
  • Page 2 General warning 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.

  • Page 3: Table Of Contents

    Contents Mounting ......5 Electrical connections ..... . . 7 Connecting diagram.
  • Page 4 linear ( CyCl= 1 ) ....39 4.4.2 Switching attitude non-linear ( CyCl= 2 ) ....39 4.4.3 Switching attitude Heating and cooling with constant period ( CyCl= 3 ) .

  • Page 5: Mounting

    Mounting Mounting KS 50-1 +0,8 min.48 (1.89") KS 52-1 SP.x +0,6 SP.X +0.02 (1.77" Safety switches è U i I (1.89") max. 60°C min. 0°C max. 10V i mA/Pt 95% rel. Ü Ü oder: Safety switch: For access to the safety switches, the controller must be withdrawn from the hou- sing.
  • Page 6 Mounting Name of safety Position Remark Factory switch setting 10V i mA/Pt right Current signal / Pt100 / thermocouple at InP. 1 Voltage signal at InP. 1 left ® open Levels as set using the BlueControl eng. tool (default): - Access to controller off / self-tuning / extended operating level = enabled - Password PASS= OFF - Access to parameter setting level /...

  • Page 7: Electrical Connections

    Electrical connections Electrical connections 2.1 Connecting diagram Electrical connections for all types KS 5x-1 exept KS 5_-1_4-_ 00_ _-_ _ 90...250V 24V AC/DC OUT1 OUT2 Logic KS 5_-1. -..-... KS 5_-1. -..-... OUT3 INP2 0..10 V INP1 Electrical connections for KS 5_-1_4-_____-__ 90...250V 24V AC/DC OUT1...

  • Page 8: Connecting Diagram For The Options Card

    Electrical connections 2.2 Connecting diagram for the options card Option KS5_-1..- ..-... 24 VDC 24 VDC +24V DC OUT5 OUT6 24V GND RXD-B RGND RXD-A TXD-B DATA B (16) DATA A TXD-A RS485 RS422 Modbus RTU According to order the controller is fitted with: flat-pin terminals combined for 1 x 6,3mm or 2 x 2,8mm to DIN 46 244 or screw terminals for conductor cross section from 0,5 to 2,5mm²...
  • Page 9 Electrical connections Connection of input INP2 3 3 INP2 current tansformer Sensor type 0...50mA AC or 0/4 ... 20 mA DC for heating current input, external set-point or external correcting variable Y.E. Connection of input di1 4 Digital input, configurable as a switch direct / inverse or a push-button.
  • Page 10 Electrical connections 6 OUT3 transmitter supply 8 2-wire transmitter supply with U 22mA 17,5V 22mA OUT3 (16) Connection of outputs OUT1 ! and OUT2 " Relay-output KS5_-1_4-_00_ _-_ _ _ and KS5_-1_5-_00_ _-_ _ _ - Relay (250V/2A), potentialfree changeover contact Connection of output OUT3 §...
  • Page 11 Electrical connections 0 RS485 interface (with RS232-RS485 interface converter) **** RGND RGND RGND R = 120...200 Ohm DATA B DATA B DATA B (16) (16) (16) DATA A DATA A DATA A R=100 Ohm converter RS485-RS232 max. 1000m RGND connection optional ”Twisted Pair”...

  • Page 12: Operation

    / error list § Up/down keys: § changing the set-point or the controller output value $ Manual mode /spec. function KS 50-1 universal (® ConF / LOGI ) % PC connection for BlueControl (engineering LED colours: tool)

  • Page 13: Behaviour After Power-On

    Operation 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 before power-off, the controller starts with the last correcting value after switching on again.

  • Page 14: Maintenance Manager / Error List

    Error list: Name Description Cause Possible remedial action   E.g. defective EEPROM   Contact PMA service E. 1 Internal error,   Return unit to our factory cannot be removed   e.g. EMC trouble   Keep measurement and power E.
  • Page 15 Operation Name Cause Possible remedial action Description   Input signal defective or not   Check heating or cooling circuit LooP Control loop alarm (LOOP)   Check sensor and replace it, if connected correctly   Output not connected correctly necessary   Check controller and switching device  ...

  • Page 16: Self-Tuning

    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: Proportional band 1 (heating) in engineering units [e.g.

  • Page 17: Self-Tuning Start

    Operation Self-tuning start 3.5.2 ® Self-tuning start can be disabled using BlueControl (engineering tool) (Conf/Othr/IAdA). Starting the self-tuning: Self-tuning is started by pressing the Ù and È keys simultaneously, or via the interface. If parameter Conf/Cntr/Strt is set to 1 self-tuning starts also af- ter power-on and when detecting process value oscillations.

  • Page 18: Optimization After Start-Up Or At The Set-Point

    Operation Optimization after start-up or at the set-point 3.5.5 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.
  • Page 19 Operation Step attempt after start-up - tunE = 0 and sufficient set-point reserve provided or Condition: - tunE = 2 The controller outputs 0% correcting variable or Y. L o and waits, until the process is at rest (see start-conditions on page 8). Subsequently, a correcting variable step change to 100% or Y.
  • Page 20 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.

  • Page 21: Optimization At The Set-Point For 3-Point Stepping Controller

    Operation Optimization at the set-point for 3-point stepping controller 3.5.7 As position feedback is not provided, the controller calculates the actuator positi- on internally by adjusting 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.

  • Page 22: Examples For Self-Tuning Attempts

    Operation Examples for self-tuning attempts 3.5.8 (controller inverse, heating or heating/cooling) 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), 100% the power is switched on (3). At the reversal point, the self-tuning t reversal point Start r...

  • Page 23: Manual Tuning

    Operation 3.6 Manual tuning The optimization aid should 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 va- riable 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.

  • Page 24: Second Pid Parameter Set

    Operation Formulas Pb1 [phy. units] td1 [s] ti1 [s] K = Vmax * Tu controller behavior 1,7 * K 2 * Tu 2 * Tu With 2-point and 0,5 * K 3-point controllers, 2,6 * K 6 * Tu the cycle time must be adjusted to t1 / t2 £...

  • Page 25: Alarm Handling

    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.
  • Page 26 Operation The variable to be monitored can be selected separately per configuration for each alarm. The following variables are available ( ConF / Lim / Src . x ): Variable (Src . x ) Remark Alarm type Process value Absolute Control deviation Process value - effective set-point.

  • Page 27: Operating Structure

    Operation 3.9 Operating structure After supply voltage switch-on, the controller starts with the operating levels. The controller status is as before power off. Ù Ù PASS PArA 3 sec. Ù Ì PASS ConF Ù PASS Ì Ù Ì PArA - level: At PArA - level, the right decimal point of the upper display line is lit continuously.

  • Page 28: Configuration Level

    Configuration level Configuration level 4.1 Configuration survey ConF Configuration level È SP. F n StYP I. F nc Fnc. 1 bAud O. A ct O. t YP Ì C. F nc S. L in StYP Src. 1 SP. 2 Addr Y.

  • Page 29: Configurations

    Configuration level 4.2 Configurations Cntr Name Value range Description Default SP. F n Basic configuration of setpoint processing set-point controller can be switched over to external set-point (-> LOGI/ SP. E ) program controller controller with start-up circuit Fixpoint / SP.E-/ SP.2 -controller with start-up circuit C.
  • Page 30 Configuration level Name Value range Description Default CYCL Characteristic for 2-point- and 3-point-controllers standard water cooling linear water cooling non-linear with constant cycle tunE Auto-tuning at start-up At start-up with step function At start-up with impulse function. Setting for fast controlled systems (e.g.
  • Page 31 Configuration level Name Value range Description Default fAI1 Forcing INP1 (only visible with BlueControl!) No forcing Forcing via serial interface InP. 2 Name Value range Description Default I. F nc Function selection of INP2 no function (subsequent input data are skipped) heating current input external set-point (SP.
  • Page 32 Configuration level Name Value range Description Default OFF..999999 Hour Operating hours (only visible with BlueControl!) OFF..999999 Swit Output switching cycles (only visible with BlueControl!) Out. 1 Name Value range Description Default O. A ct Method of operation of output OUT1 direct / normally open inverse / normally closed Y.
  • Page 33 Configuration level Name Value range Description Default transmitter supply (only visible without OPTION) O. A ct Method of operation of output OUT3 (only visible when O.TYP=0) direct / normally open inverse / normally closed Y. 1 Controller output Y1/Y2 (only visible when O.TYP=0) Y.
  • Page 34 Configuration level LOGI Name Value range Description Default Local / Remote switching (Remote: adjusting of all values by front keys is blocked) no function (switch-over via interface is possible) active DI2 (only visible with OPTION) DI3 (only visible with OPTION) è...
  • Page 35 Configuration level Name Value range Description Default C. o FF Switching off the controller no function (switch-over via interface is possible) DI2 (only visible with OPTION) DI3 (only visible with OPTION) è - key Ò - key m. L oc Blockage of hand function no function (switch-over via interface is possible) DI2 (only visible with OPTION)
  • Page 36 Configuration level othr Name Value range Description Default bAud Baudrate of the interface (only visible with OPTION) 2400 Baud 4800 Baud 9600 Baud 19200 Baud Addr 1...247 Address on the interace (only visible with OPTION) PrtY Data parity on the interface (only visible with OPTION) no parity (2 stop bits) even parity odd parity...
  • Page 37 Configuration level Name Value range Description Default IAda Block auto tuning (only visible with BlueControl!) Released Blocked Block extended operating level (only visible with IExo BlueControl!) Released Blocked ® Suppression error storage (only visible with BlueControl ILat OFF...9999 Password (only visible with BlueControl!) Pass IPar Block parameter level (only visible with BlueControl!)

  • Page 38: Set-Point Processing

    Configuration level 4.3 Set-point processing The set-point processing structure is shown in the following picture: Xeff SP.x internal set-point Boost Ü ù SP. H i Programmer SP. L o Start-up circuit external Limitation effective SP. E set-point Ö r. S P set-point INP2 0/4...20 mA...
  • Page 39 Configuration level prevent unreasonably short on and off pulses. The shortest pulses result from ¼ x t1 or ¼ x t2. The characteristic curve is also called “bath tub curve”. T / T 4 x t1 3 x t1 2 x t1 25 30 70 75 Controller output [%]...

  • Page 40: Heating And Cooling With Constant Period ( Cycl= 3 )

    Configuration level very weak. Moreover, the correcting variable increases very quickly to max. possi- ble cooling. Parameter F. H 2O can be used for changing the characteristic curve. The standard method (see section 4.4.1) is also used for heating. Cooling is also enabled dependent of process temperature .

  • Page 41: Configuration Examples

    Configuration level 4.5 Configuration examples On-Off controller / Signaller (inverse) 4.5.1 SP. L O SP. H i InL. 1 InH. 1 InP. 1 Ê 100% Out. 1 Â HYS. L HYS. H ConF / Cntr: SP. F n = 0 set-point /cascade controller C.

  • Page 42: 2-Point And Continuous Controller (Inverse)

    Configuration level 2-point and continuous controller (inverse) 4.5.2 SP. L O SP. H i InL. 1 InH. 1 InP. 1 Ê 100% Out. 1 Â 20 mA Out. 3 Â 0/4 mA SP. F n ConF Cntr set-point / cascade controller C.

  • Page 43: 3-Point And Continuous Controller

    Configuration level 3-point and continuous controller 4.5.3 SP. L O SP. H i InL. 1 InH. 1 InP. 1 Ê Out. 1 Â 100% 100% Out. 2 Â Out. 3 Â 20 mA 0/4 mA ConF / Cntr: SP. F n = 0 set-point / cascade controller C.

  • Page 44: 3-Point Stepping Controller (Relay & Relay)

    Configuration level 3-point stepping controller (relay & relay) 4.5.4 SP. L O SP. H i InL. 1 InH. 1 InP. 1 Ê Out. 1 Â 100% 100% Out. 2 Â ConF / Cntr: SP. F n = 0 set-point / cascade controller C.

  • Page 45: D - Y - Off Controller / 2-Point Controller With Pre-Contact

    Configuration level D - Y - Off controller / 2-point controller with pre-contact 4.5.5 SP. L O SP. H i InL. 1 InH. 1 InP. 1 Ê 100% 100% Out. 1 Â Out. 1 Â Out. 2 Â d. S P ConF / Cntr: SP.

  • Page 46: Ks50-1 With Measured Value Output

    Configuration level KS5_-1 with measured value output 4.5.6 phys. quantity Out. 1 mA / V phys. quantity Out. 0 0/4mA 20mA 0/2V Example: KS5_-1_2-_00_ _-_ _ _ 90...250VAC 24VUC OUT3 INP1 ConF / Out. 3 : O. t YP = 1 Out.

  • Page 47: Parameter Setting Level

    Parameter setting level Parameter setting level 5.1 Parameter survey PArA Parameter setting level È Ì Pb12 SP. L o b. L o InL. 1 Inl. 2 L. 1 Pb22 SP. H i b. H i OuL. 1 OuL. 2 H. 1 ti12 SP.

  • Page 48: Parameters

    Parameter setting level Press the Ù - key to change to the next parameter. After the last parameter of a group, donE is displayed and followed by auto- matic changing to the next group Return to the beginning of a group, by pressing the Ù key for 3 sec. Unless a key is pressed during 30 seconds, the controller returns to the process value and setpoint display ( Time Out = 30 sec.
  • Page 49 Parameter setting level PAr. 2 Name Value range Description Default Pb12 1...9999 1 Proportional band 1 (heating) in phys. dimensions ( e.g. °C), 2. parameter set Pb22 1...9999 1 Proportional band 2 (cooling) in phys. Dimensions (e.g. °C), 2. parameter set Ti22 0...9999 Integral action time 2 (cooling) [s], 2.
  • Page 50 Parameter setting level InP. 1 Name Value range Description Default InL. 1 -1999...9999 Input value for the lower scaling point OuL. 1 -1999...9999 Displayed value for the lower scaling point InH. 1 -1999...9999 Input value for the upper scaling point OuH.

  • Page 51: Input Scaling

    Parameter setting level 5.3 Input scaling When using current or voltage signals as input variables for InP. 1 or InP. 2 , scaling of input and display values at parameter setting level is required. Specifi- cation of the input value for lower and higher scaling point is in the relevant elec- trical unit (mA/ V).

  • Page 52: Calibration Level

    Calibration level Calibration level CAL) Measured value correction ( is visible only if ConF / InP. 1 / Corr = 1 or 2 is selected. To access the calibration level, press the key Ù for 3 seconds and then the key Ì...
  • Page 53 Calibration level ( ConF/ InP. 1 / Corr =1 ): Offset correction possible on-line at the process display standard setting offset correction OuL. 1 OuL. 1 InL. 1 2-point correction ( ConF/ InP. 1 / Corr = 2): Ù PArA SP.X Ì...
  • Page 54 Calibration level InH. 1 : The input value of the upper scaling point is displayed. . The operator must adjust the upper input value by means of the process value simulator and confirm the input value by pressing key Ù. OuH.

  • Page 55: Programmer

    Programmer Programmer SP. 0 1 SP. 0 2 SP. 0 9 SP. 1 0 Pt. 0 1 Pt. 0 2 Pt. 0 3 Pt. 1 0 Programmer set-up: For using the controller as a programmer, select parameter Cntr /SP. F n = 1 in the ConF menu.

  • Page 56: Special Functions

    Special functions Special functions 8.1 Start-up circuit Set-point Process value SP. S t SP. S t-1K SP. S t-40K t. S t t. S t Disturbance Power on The start-up circuit is a special function for temperature control, e.g. hot runner control.

  • Page 57: Boost Function

    Special functions 8.2 Boost function W + SP. b o Set-point Process value SP. b o The boost function causes short-time increase of the set-point, e.g. for removing "frozen" material rests from clogged die nozzles with hot-runner control. If configured (® ConF/ LOGI/ booS), the boost function can be started via di- gital input di1/2/3, with the function key on the instrument front panel or via the interface (OPTION).

  • Page 58: Ks50/52-1 As Modbus Master

    Special functions 8.3 KS50/52-1 as Modbus master This function is only selectable with BlueControl (engineering tool)! Additions othr (only visible with BlueControl!) Name Value range Description Default MASt Controller is used as Modbus master Slave Master 0...200 Cycl Cycle time [ms] for the Modbus master to transmit its data to the bus.

  • Page 59: Linearization

    Special functions 8.4 Linearization Linearization for input INP1 Access to table “ Lin” is always with selection of sensor type S.TYP = 18: special thermocouple in INP1, or with selection of linearization S. L in 1: special linearization. Dependent of input type, the input signals are specified in µV or in Ohm dependent of input type.

  • Page 60: Bluecontrol

    Software comprises all functions of the Expert-version. All BluePort devices can be triggered via this software. The mini version is - free of charge - at your disposal as download at PMA home- page www.pma-online.de or on the PMA-CD (please ask for).

  • Page 61: Versions

    Versions Versions K S 5 KS 50-1 Format 48 x 96 KS 52-1 Format 96 x 96 Flat pin connector Screw terminals 90..250V AC,INP2, 3 relays 24VAC / 18..30VDC, INP2, 3 relays 90..250V AC, INP2, 2 relays+ mA/V/logic 24VAC / 18..30VDC, INP2, 2 relays+ mA/V/logic 90..250VAC, 2 relays (Wechsler) + mA/V/logic...
  • Page 62 French 9499-040-62832 Operating manual Russian 9499-040-62865 Interface description Modbus RTU German 9499-040-63618 Interface description Modbus RTU English 9499-040-63611 BlueControl (engineering tool) Mini Download www.pma-online.de BlueControl (engineering tool) Basic 9407-999-11001 BlueControl (engineering tool) Expert 9407-999-11011 BlueControl (engineering tool) Universal 9407-999-19011 KS50/52-1...

  • Page 63: Technical Data

    Technical data Technical data CONTROL INPUT DI1 Configurable as switch or push-button (the adjust- INPUTS ment is possible only in common for all digital inputs)! Connection of a potential-free contact suitable for PROCESS VALUE INPUT INP1 switching “dry” circuits. Resolution: >...
  • Page 64 Technical data OUTPUTS OUTPUTS OUT5, OUT6 (OPTION) Galvanically isolated opto-coupler outputs. RELAY OUTPUTS OUT1, OUT2 Grounded load: common positive voltage. Output rating: 18...32 VDC; ≤ 70 mA Contact type: KS5_-1_0-_00_ _-_ _ _ KS5_-1_1-_00_ _-_ _ _ Internal voltage drop: ≤ 1V with I .
  • Page 65 Technical data Altitude To 2000 m above sea level Certifications Shock and vibration Type tested to EN 14597 (replaces DIN 3440) Vibration test Fc (DIN 68-2-6) With certified sensors applicable for: Frequency: 10...150 Hz Heat generating plants with outflow Unit in operation: 1g or 0,075 mm temperatures up to 120°C to DIN 4751 Unit not in operation:...

  • Page 66: Safety Hints

    Safety hints Safety hints This unit was built and tested in compliance with VDE 0411-1 / EN 61010-1 and was delivered in safe condition. The unit complies with European guideline 2004/108/EG (EMC) and is provided with CE marking. The unit was tested before delivery and has passed the tests required by the test schedule.
  • Page 67 Modification, maintenance and repair work may be done only by trained and aut- horized personnel. For this purpose, the PMA service should be contacted. The cleaning of the front of the controller should be done with a dry or a wetted (spirit, water) kerchief.

  • Page 68: Reset To Default

    Safety hints 12.1 Reset to default ÌÈ È Ù + Power on 8. 8 . 8 . 8 . SP.x SP.x SP.x SP.x SP.x 8. 8 . 8 . 8 . COPY torY In the event of faulty configuration, the instrument can be reset to default. In the event of faulty configuration, the instrument can be reset to default.
  • Page 69 Index Digital inputs di1, di2, di3 2-point correction... . 55 Configuration ..34 Technical data ..64 Accessories .
  • Page 70 Set-point processing ..38 Offset correction ... . 54 Start-up circuit ... . . 57 Optimization at the setpoint .
  • Page 71 KS50/52-1...
  • Page 72 9499- 040- 62811 Subject to alterations without notice © PMA Prozeß- und Maschinen-Automation GmbH Änderungen vorbehalten P.O.B. 310 229, D-34058 Kassel, Germany Sous réserve de toutes modifications Printed in Germany 9499-040-62811 (08/2013)

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