Advanced line, cyclic transmission of up to 16 input and 16 output values, free definition of data content, transmission of process and parameter data, inputs and outputs as decentral io (4 pages)
(e.g. 8-channel three-point stepping controller and digital in- puts). Basic structure The basic KS 800 structure for control function handling is shown below. The unit is divided into four main groups: input functions...
Multi-Temperature-Controller KS 800 Signal distribution The conditioned input signals are passed to the controller cyclically (together with the relevant control parameters). Functions Sequence control The sequence control describes the statuses and priorities in the control algorithm and the condi- tions and signals for other function statuses.
0...1000°C ) not acc. to DIN The lower measuring limit of KS 800 is 0 mV for all thermocouple types, i.e. 0°C or 32°F. The upper measuring limit is the upper operating temperature of the relevant thermocouple type. The thermocouples are monitored for wrong polarity and break.
Multi-Temperature-Controller KS 800 2.3.2 Resistance thermometer Resistance thermometers of type PT 100 to DIN/IEC 751 can be connected in 2 or 3-wire circuit. The lower measuring limit is -100°C. The upper measuring limit is +850°C. The thermometer current is approx. 0,25 mA.
Multi-Temperature-Controller KS 800 Measurement value correction A method which permits zero offset, gain adjustment both combined by 4 parameters is used. X2out X2in X1out X1in Measured input value The parameters can be determined for any working points: X1in old displayed start value...
Multi-Temperature-Controller KS 800 2.4.1 Application examples: The units can be any variables. 1. Gain adjustment The straight line from 0 ... 900 shall be 105 instead of 100 in working point 100. x1in and x1out = 0 , x2in = 100 and x2out = 105.
Multi-Temperature-Controller KS 800 2.5.3 Digital input signals Signal description Conn. terminal Active with Par1/Par2 IN/OUT13 C700_1 = 3 W/W2 IN/OUT16 C190_1 = 1 Coff IN/OUT14 C190_2 = 1 Leck IN/OUT15 C500_2 = 4 Par1/Par2: Parameter switch-over. Each controller can contain 2 parameter sets, which can be activated by selection.
Multi-Temperature-Controller KS 800 Controller block diagram Function for each controller (8 x per unit) Sequence control Controller status control Adaptation Start-up circuit Sequence control Controlled adaptation Controller self-tuning Mean value for output control Closed loop control Signaller 1 output Signaller 2 output...
Setpoint processing for set-point control The effective set-point for KS 800 is handled by various pre-processing functions, before it is used for the control algorithm. When the controller is switched on, the non-volatile set-point Wnvol is effective, i.e. Wvol = Wnvol.
Function block protocol Data structure Due to the large variety of information processed in KS 800, logically related data and actions are grouped in function blocks. A function block has input and output data, parameter and confi- guration data. 41 function blocks are defined for KS 800. They are addressed via fixed block addresses (FB no.).
Multi-Temperature-Controller KS 800 Structure of configuration words The configuration words listed in the following code tables comprise several partial components which can be transmitted only in common. The data in the table must be interpreted as follows: Example Code Descr.
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Multi-Temperature-Controller KS 800 To A: Unit_State1 Bit no. Name Allocation Status "0" Status "1" "0" always "0" instrument status online configuration D2...D4 "0" always "0" parameter update "1" always "0" parity To B: DP Err Bit no. Name Allocation Status "0"...
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Multi-Temperature-Controller KS 800 To D: SWopt Version "10³" "10²" "10" "1" Basic version Water cooling To E: SWCod "10³" "10²" "10" "1" 7th digit 6th digit 5th digit 4th digit Example: Value "SWCod = 7239" means that the software for the addressed instrument contains code number 4012 157 239xx.
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Multi-Temperature-Controller KS 800 To H: State_alarm_out Bit no. Name Allocation Status "0" Status "1" Relay 1 Relay 2 Relay 3 do 1...12 AL Alarm output short circuit OUT1...OUT12 HCscAL Alarm output heating current short circuit "ß" always "0" "1" always "1"...
Multi-Temperature-Controller KS 800 Controller statuses and status priorities The priorities are sorted according to ascending order (0=low; 7=high) Priority 0 automatic (low) The controller is in automatic mode (control operation). Set-point definition is possible. Priority 1 Tune, run Self-tuning is active and handles the self-tuning procedure independently.
Multi-Temperature-Controller KS 800 Priority 2 Tune, error When the controller self-tunging was finished or cancelled with an error, the controller switches over to manual mode and outputs a constant correcting variable with the value of stable correc- ting variable YOptm. Adjustment of the manual correcting value via interface is not possible in this status.
Multi-Temperature-Controller KS 800 Priority 7 Y_Track During the Y_Track status, the controller tracks the correcting variable to a pre-defined value. The function is handled internally by the controller. The operating principle is described exactly in section Cascade control. Priority 8 Controller off (high)
Multi-Temperature-Controller KS 800 Automatic - manual switch-over According to determination, automatic - manual switch-over via the interface is possible. The controller statuses resulting from the signal priority are as follows: Priority Controller Y-Track Controller Sensor failure Controller status manual Automatic...
Multi-Temperature-Controller KS 800 Self-tuning for single-loop controllers For determination of the optimum control parameters, controller self-tuning is possible. Optimi- zation can be started and finished from automatic or manual mode. It is also active with the start- up circuit configured.
Multi-Temperature-Controller KS 800 8.1.3 Start from automatic mode After starting, the stable correcting variable YOptm is output and the controller waits, until the process is at rest. When "process at rest" was detected, self-tuning starts automatically. During this time, the set-point can be changed.
Multi-Temperature-Controller KS 800 Set-point monitoring For keeping the process at a safe state, continuous monitoring prevents the set-point from being exceeded. When exceeding the set-point, self-tuning is cancelled, an error message is genera- ted, the controller switches over to manual mode and the stable correcting variable YOptm is output.
Multi-Temperature-Controller KS 800 8.5.4 Common start of the cooling attempt for all 3-point heating/cooling controllers After group controller self-tuning was started by the coordination function, no further controller coordination is required. Exception: If 3-point heating/ cooling controllers participate in the attempt, the cooling attempt of these controllers is started in common by the coordinator function.
Multi-Temperature-Controller KS 800 Increase separationof Cancellation: Optimisation cancelled due to exceeded set- process value (X) and point risk. set-point (W) during start-up. Finished: Optimisation cancelled due to exceeded set-point risk (reversal point not reached so far safe estimation). increase Ymax or Cancellation: reduce YOptm.
Multi-Temperature-Controller KS 800 Control function parameters The default parameters marked with x are adjusted dependent of version. Signaller 2-pnt. 3-pnt. con- 3-pnt. 1 output 2 outputs contr. troller stepp.con- heat./cool. troller Para- Range Default meter 0,1...999,9 0,1...999,9 0...9999 0...9999 0,4...999,9 0,4...999,9...
Multi-Temperature-Controller KS 800 Signaller Signalling function The signalling function is a controller function and must be specified for each individual controller by configuration C100_3. This configuration can be used for processes with low Tu and small Vmax. The control oscilla- tions can be determined by: X0 = Xmax ×...
Multi-Temperature-Controller KS 800 Two-point controller The parameters required for this controller are tranferred from: Function block controller type no.:91, function Parameter set x, function number 6 and 7. (Function number 6 = parameter set 1; function number 7 = parameter set 2) Abbr.
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Multi-Temperature-Controller KS 800 Xp1 = 100% 100% direct working- point Y0 inverse x, w The static characteristic of the two-point controller is identical with the one of the continuous controller. The difference is that a duty cycle instead of a linearly variable current signal is output (relay contact, control output 0/24V).
Multi-Temperature-Controller KS 800 Three-point DPID controller The parameters required for this controller are transferred from: Function block controller type no.:91, function Paramset x, function number 6,7. Abbr. Description Range Default Proportional band 1 0,1...999,9 % 100 % Integral time 1 0...9999 sec...
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Multi-Temperature-Controller KS 800 The figures show the static characteristic for inverse and direct action with Tn = 0. Direct / in- verse switch-over only causes an exchange of the outputs for "heating/cooling". The terms "hea- ting" and "cooling" are used accordingly for all similar processes (batching acid/lye, ...). The neutral zone is adjustable separately for the trigger points (Xsh1, Xsh2) and need not be sym- metrical to the set-point.
Multi-Temperature-Controller KS 800 Three-point stepping controller In order to match the adjusted Xp1 to the motor actuator travel time, the travel time Tm must be adjusted. The smallest positioning step of the controller is 0,1sec. Adjusting the neutral zone With excessively frequent output switching, the neutral zone X can be increased.
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Multi-Temperature-Controller KS 800 In the figure below, the static characteristics of the three-point stepping controller configured as inverse and direct is shown. The hysteresis shown in this figure is practically without importance, however, it can be calculated from the adjustable pulse length Tpuls <10ms.
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Multi-Temperature-Controller KS 800 Controller structure: Three-point stepping controller Controller configuration C101 CMode 0, CDiff 0, Cfail 1, CAnf 0 Controller configuration C100 CFunc 07, CType 0, Wfunc 0 Function block controller type no.:91, function Algorithm function no.: 3 neutral zone in % referred to X0...X100 of variable input 1 actuator response time in sec Tpuls min.
Forcing of switching outputs Input and output "forcing" means determination of the input or output level from a control system. With KS 800, the outputs for heating (OUT1...OUT8) and cooling (OUT9...OUT12 and IN/OUT13...IN/OUT16) can be "forced" (only output forcing). As a general rule, outputs which are not used for a control function are enabled for forcing:...
Multi-Temperature-Controller KS 800 Continuous controllers With KS 800, up to 8 outputs can be used as continuous controllers. Standard current or stan- dard voltage output signal is dependent of hardware. With standard current signal, switch-over between "dead zero" (0...20 mA) or "live zero"...
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Multi-Temperature-Controller KS 800 Xp1 = 100% 100% direct working- point Y0 inverse x, w PD-behaviour ( Tn = 0 ) The working point is determined with X=W output Y = 50% +Y0. For keeping the process lined out, a certain amount of energy dependent of set-point is required.
Multi-Temperature-Controller KS 800 Water cooling KS 800 is equipped with a special control algorithm for water cooling which is activated if con- figured accordingly. This setting is possible separately for each channel. The evaporation effect occurs only above defined temperatures. Water cooling below these temperatures can be disabled.
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Multi-Temperature-Controller KS 800 Definitions: Duration of cooling pulse (Parameter) The cooling pulse duration is constant. It is adjusted by parameterT (which is already puls provided). (min. switch-on pulse with 3-point stepping controllers). Dependent of the control function configuration, the signification of T...
Multi-Temperature-Controller KS 800 Control parameters T and T for the cooling controller There are important differences in the dynamic conditions for heating and cooling processes. Therefore, independent parameters for heating (X ) and cooling (X ) are determined during self-tuning with water cooling controllers. Switch-over is automatic when the correcting variable passes the zero with a hysteresis of 2% symmetrical to the zero.
Multi-Temperature-Controller KS 800 Cascade control For cascade control, one master and one or several slave controllers the set-point of which is the analog master control output are used. As long as cascade control remains at two levels (1 master controller with 1 level slave control- lers) any combination is possible: from 1 master with 7 slaves up to 4 masters with 4 slaves.
Multi-Temperature-Controller KS 800 Special input signals of the cascade controller for cascade operation: Wext: The master provides a continuous output signal Ypid in 0 ... 100%, which is connected with the internal Wext input of the cascade controller - as configured in C180.
Multi-Temperature-Controller KS 800 17.4 Example of cascade control with up to 7 slave controllers w_w2 Coff CASC_open wi_e "or" cfail Ypid Wext orun Master Slave 1 track_y y_track Standardisation 0...100% Xeffn w_w2 Coff wi_e CASC_open "or" cfail orun Wext Slave 2 Standardisation 0...100%...
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Multi-Temperature-Controller KS 800 Configuration of the master controller: C100_43 = 02 (master with output Ypid) C100_1 (set-point) C180_3 (no Wext) Configuration of slaves: C100_43 = any C100_1 (set-point / cascade) C101_2 (last mean Y) C180_3 (Wext = Ypid from master channel x=1-8) The operating principle is as described for simple cascade control.
Multi-Temperature-Controller KS 800 Start-up circuit The start-up function is a controller function and must be specified for each individual controller by configuration C101_1 = 1 (with start-up circuit). The start-up function only remains active if the controller runs in automatic mode; any other mode causes cancellation of the start-up function.
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Multi-Temperature-Controller KS 800 ANFAHR_HALTETZEIT status When the process value falls by > LCA (40K, fixed), the start-up circuit switches to the AN- FAHR_LIMIT_Y status. When the set-point for normal mode (W) falls below the requested start- up set-point (Wa), the holding time is cancelled and the start-up circuit switches to the AN- FAHR_OFF status.
Multi-Temperature-Controller KS 800 Mean value formation for the output hold function Mean value formation is only effective for configuration with C101_2 = 5. The parameters required for this purpose are transferred from: Mean value formation is a controller function and must be specified for each individual controller by configuration C101_2.
Multi-Temperature-Controller KS 800 Heating current monitoring 20.1 Heating current monitoring The heating current monitor is limited to controller outputs 1...8 and provides monitoring for heating circuit undercurrent and actuator short circuit. Monitoring can be done at an adjustable cycle: All controllers except the one to be monitored are switched off (independent of control) and the heating current is measured.
Multi-Temperature-Controller KS 800 tting) and the measured value is transmitted in the 3. cycle. For electromechanical switching elements, the measurement time must be extended considering the inertia. This is by entry a "8" in the hundreds position (e.g. 854). The cycle time remains unchanged.
Multi-Temperature-Controller KS 800 Evaluation of heating current measurement The measuring range of the heating current input is 30mA AC for direct connection to standard current transformers. Below HC100, specification which current (in A) actually flows when the current transformer delivers 30mA AC is required.
A scaling factor is applicable to all converters in conjunction with KS 800. The KS 800 heating current input was initially designed for a converter with a transmission ratio of 1:1000, at a max. primary current of 30A, i.e. I = 30mA.
Multi-Temperature-Controller KS 800 Alarm handling For each controller, four alarm trigger points can be adjusted independently (without determina- tion of names and abbreviations!). However, using the expressions used in the drawing is purpo- seful. The switching hysteresis is equal for all four trigger points.
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Multi-Temperature-Controller KS 800 W100 high alarm xsd1 xsd1 high/high alarm low/low xsd1 xsd1 Configuration word C600 and C601 determines which signal shall be monitored by the alarm function and how the alarm functions are used. Function block alarm type no.:46, function General, function number 0.
Multi-Temperature-Controller KS 800 Configuration 23.1 General The KS800 controller configuration is described in this section. In the configuration, the function required for an application are selected from a variety of functions. By configuration, the basic structure for an application solution is determined. Digits which cannot be selected are marked by an "0".
Multi-Temperature-Controller KS 800 Wfunc: (set-point function) Set-point W Set-point/cascade W (with slave controller: W = Y from ma- ster controller) 23.2.1.1 C101 additional controller configuration (adjustable per controller) The following additional adjustments are possible via the additional controller configuration: C101...
Multi-Temperature-Controller KS 800 23.2.2 Control loop monitoring (loop alarm) (adjustable individually for each controller) Control loop monitoring can be activated individually for each controller. Hereby, the overall control loop comprising sensor, controller, switching element, (power) fuse, heatingg or cooling and all leads is monitored.
Multi-Temperature-Controller KS 800 Control loop monitoring is controlled via configuration word C102: C102 Digit Description LoopOn Default Definition always LoopOn: control loop monitoring 23.2.3 C150 Heating current and output monitoring and additional configuration C151 (ad- justable for each unit) Adjustment of cycle time for heating current, leakage current and output monitoring (ad-...
Multi-Temperature-Controller KS 800 23.2.3.1 C151 additional heating current configuration (adjustable for each unit) The additional heating current configuration determines the output of the heating current statuses to the alarm output. C151 Digits Description DestHC DestLeck DestOuterror Default Determination always DestHC:...
Multi-Temperature-Controller KS 800 23.2.5 C190 digital signal allocation Control signals for set-point processing (adjustable for each controller) C190 Digits Description SCoff Sw/W2 Default Determination always Scoff: (switch off controller outputs of control function) controller can only be switched off via the interface separately for each individual...
Multi-Temperature-Controller KS 800 23.3 Inputs In this main group, the signal inputs for the selected controller configuration are determined. Like with the control function configuration, a large number of applications can be covered by determi- nation of the main configuration.
Multi-Temperature-Controller KS 800 23.3.2 Input scaling Input scaling is only possible with DC voltage input. With input scaling, different physical quanti- ties are allocated to the electrical input voltages for (span) start and end. (e.g. 0mV 0l/h and 80mV 1000l/h; 0mV...
If the sensor of controller 8 is a ther- mocouple, compensating lead must be used up to KS 800. If the sensor is a resistance thermometer, copper lead can be used.
Multi-Temperature-Controller KS 800 23.4 Configuration examples 23.4.1 Thermocouples With a thermocouple, the type of temperature compensation, the TC value and the signal beha- viour with sensor break can be determined. The behaviour is determined with configuration word C205. Configuration of: C200, C205, C210, C213, C214 23.4.2 Resistance thermometer...
Entry of output level via the interface (forcing) Cooling output of controller 5 Switch over parameter set 1/2, 1 input for all controllers configured accordingly General digital input, no processing in KS 800, evaluation via the system bus. Fkt_dio2: (IN/OUT14)
Multi-Temperature-Controller KS 800 23.5.3 Analog outputs In addition to the function as (analog) controller outputs, these analog outputs can output also other variables (transmitter function): process value set-point correcting variable forcing The dead zero (0...20mA) or live zero (4...20mA) output range is determined in common for all analog outputs (in C904) and independent of use (allocation) of the individual outputs.
Multi-Temperature-Controller KS 800 23.5.3.1 C600, C602, C603, C604 type of alarms In C600, C602, C603 and C604, the alarm type is configured (adjustable individually for each controller). With common alarm configuration selected in C904, there is only C600, which is valid for all alarms.
Multi-Temperature-Controller KS 800 23.5.3.2 C601 alarm target In C601, the target for output of a trigger point to the output is configured (adjustable for each controller). C601 Digits Description DestLL DestL DestH DestHH Default Determination always always always always DestLL:...
Multi-Temperature-Controller KS 800 23.5.4 C700 controller self-tuning For adjustment of the type of controller self-tuning and type of controlled adaptation (adjustable for each unit). C700 Digits Description OMode OCond OGrp OCntr Default Determination OMode: (controller self-tuning) based on the calculated process characteristics Tu and Vmax.
Note: Preset address "0" should not be changed. As this interface provides a "point-to-point connection", address changing is not purposefull. If this address is changed into an un- known address, building up the communication between PC and KS 800 again is very difficult.
Multi-Temperature-Controller KS 800 23.5.6 COM2 interface Address and Baudrate for the COM2-interface can be adjusted for each KS 800 via hardware or software. Hardware address adjustment is possible within "01" and "99". In position "00", the address stored in EEPROM is taken over during switch-on and can be changed via software. The ad- dress adjusted by switch position has priority and cannot be changed via software.
Multi-Temperature-Controller KS 800 23.5.6.1 C902 Baud rate COM2 bus interface The Baudrate of the serial interface COM2 (bus interface, sub-D connector) is configured in this configuration word (individually adjustable for each instrument). The Baudrate must be identical with master (PLC, operating unit) and KS800, otherwise, no communication is possible.
Multi-Temperature-Controller KS 800 23.5.7 C904 mains frequency, alarm and current output configuration For optimum suppression of mains frequency interference, the mains frequency can be configured in Frq . From operating version 5 and instrument number 8385 (January 2002) configuration of the four limit values for each controller channel is possible individually on Alm-Ver : alarm source, funct- ion and error output.
Multi-Temperature-Controller KS 800 Annex Special functions For some users, KS 800 was equipped with special functions according to the user specifica- tions. These functions are not of general interest and need not be taken into account by the normal user.
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With the alarm limits switched off, the measurements are treated as if the range was not excee- ded, i.e. mean value formation is always provided. KS 800 does not recognize settings which do not make sense, e.g. two adjacent controllers are mean value controllers. These preclusions must be taken into account by the programmer.
Multi-Temperature-Controller KS 800 24.1.1 Configuration This special function is activated in configuration word C100. Mean value formation is determined in digit 2. (For better clarity, the overall configuration word C100 is described again below.) C100 Digit Description CFunc Wfunc Default...
Safety limiter with holding function Each one of the 8 KS 800 controllers can be used as a safety limiter with holding function. If this alarm contact has responded once, it does not return to the "good condition" automatically. For de-activating the alarm, 2 conditions must be met: 1.
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